GC4035 (HC) P35 (P20 P45) CVD-coated carbide grade for roughing of

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1 NRL TURNIN Turning P Steel, cast steel, long chipping malleable iron. asic grades T5005 (T) P05 (P01 P10) n uncoated titanium-based cemented carbide a cermet. This grade is designed to give maximum performance in super-finishing of steel and cast-iron when exceptional surface finish is required. T5015 (T) P10 (P01 P20) n uncoated cermet witcellent resistance to built-up-edge and plastic deformation. New formula with improved toughness. or finishing of low alloy and alloy steels when high surface quality and/or low cutting force are required. x a p < 0.35 mm () P15 (P05 P25) PV coated cermet with very high wear resistance and good edge toughness. or finishing and semi-finishing of low carbon and low alloyed steels. To be used when good surface quality is demanded at medium to high cutting speeds. x a p < 0.35 mm 2. P Steel NSI asic grades T 5005 T () P05 (P01 P15) V-coated grade witcellent resistance to crater wear and plastic deformation. very good choice when machining dry, long engagement times or high cutting speeds. or medium to rough steel turning applications () P15 (P01 P30) V-coated carbide grade for finishing to light roughing of steel and steel castings at high cutting speeds in wet and dry applications. Is able to withstand high temperatures without sacrificing edge security () P25 (P10 P35) V-coated carbide grade for finishing to roughing of steel and steel castings. The combination of a wear resistant coating and a tough substrate allows the grade to handle continuous cuts as well as interrupted cuts at high metal removal rates () P35 (P20 P45) V-coated carbide grade for roughing of steel and steel castings under unfavorable conditions. The tough substrate allows the grade to handle interrupted cuts at high metal removal rates omplementary grades 1025 () P25 (P10 P35) PV-coated micro-grain carbide. Recommended for finishing of low carbon steel and other sticky steel alloys when excellent surface finish or sharp cutting action is needed. reat resistance to thermal shock makes it also suitable for intermittent cuts () P25 (P20 P30) V-coated carbide grade. ombined with geometries providing sharp cutting action, this grade is recommended for finishing to light roughing of carbon steels and other sticky alloys 2025 () P35 (P25 P40) V-coated carbide grade. lternative choice for toughness demanding steel applications. 235 () P45 (P30 P50) V-coated carbide grade for roughing of steel and steel castings under the most unfavourable conditions. The tough substrate provides extremely good edge security which allows the grade to handle heavy interrupted cuts at low speeds. omplementary grades Toughness Wear resistance Letter symbols specifying the designation of hard cutting materials: ardmetals: W T Uncoated hardmetal containing primarily tungsten carbide (W) Uncoated hardmetal, also called cermet, containing primarily titanium carbides (TI) or titanium nitrides (TIN) or both. ardmetals as above, but coated. The position and form of the grade symbols indicate the suitable field of application. entre of the field of application. } Recommended field of application. 67

2 NRL TURNIN M ustenitic/ferritic/martensitic stainless steel, cast steel, manganese steel, alloy cast iron, malleable iron, free cutting steel. asic grades 1025 () M15 (M10 M25) PV-coated micro-grain carbide. Recommended for finishing of stainless steels when close tolerances, excellent surface finishes or sharp cutting action is needed. reat resistance to thermal shock makes it also suitable for intermittent cuts () M15 (M05 M25) V-coated carbide grade for finishing and light roughing of stainless steels. substrate, which can handle high temperatures, combined with a wear resistant coating makes this grade a first choice for continuous cuts at moderate to high cutting speeds () M25 (M15 M35) V-coated carbide optimized for semifinishing to roughing of austenitic stainless and duplex stainless steels at moderate cutting speeds. ood resistance to thermal shock and mechanical shock provides excellent edge security also for interrupted cuts () M35 (M25 M40) PV-coated carbide. Recommended for semi-finishing to roughing of austenitic stainless and duplex stainless steels at low to moderate cutting speeds. reat resistance to thermal shock makes it ideal for applications with fast intermittent cuts. omplementary grades 1525 () M10 (M05 M15) PV coated cermet. Very high wear resistance and good edge toughness. Low smearing tendency. xellent for finishing of stainless steel under favorouble conditions. To be used at high speeds and relatively low feeds. x a p < 0.35 mm () M15 (M05 M20) PV-coated carbide. The combination of a hard fine grain substrate with good plastic deformation resistance and a coating with high wear resistance at high temperatures, makes this grade suitable for finishing of stainless steels at high speeds () M15 (M05 M20) V-coated carbide grade for finishing to light roughing of stainless steels. The combination of a wear resistant coating and a tough substrate makes the grade suitable for stainless steel castings () M25 (M15 M30) V-coated carbide grade, which may be used for semi-finishing to roughing of stainless steels at moderate cutting speeds. ood resistance to thermal shock and mechanical shock provides excellent edge security also for interrupted cuts. 235 () M40 (M25 M40) V-coated carbide grade for roughing of stainless steels and stainless steel castings with difficult skin. The tough substrate provides extremely good edge security which allows the grade to handle heavy interrupted cuts at low to moderate speeds. K ast iron, chilled cast iron, short chipping malleable iron. asic grades 650 (M) K01 (K01 K05) Mixed l2o3-based ceramic. Recommended for high speed finishing of grey cast irons and hardened cast irons under stable conditions. 7050/50 (N) K05 ( K01 K10 n extremely hard ubic oron Nitride grade. igh edge toughness and good wear resistance makes it optimal for high speed finishing of grey cast iron under continuous as well as interrupted conditions () K10 (K01 K20) Pure silicon nitride based ceramic providing good wear resistance at high temperatures. Recommended for high speed roughing to finishing of cast irons under good conditions. Is able to handle some interruptions () K10 (K05 K15) V coated silicon nitride ceramic grade. The properties of 1690 makes it highly recommendable for light roughing, medium and finishing applications in cast iron () K05 (K01 K15) V-coated cemented carbide consisting of a thick, smooth wear resistant coating and a very hard substrate. Recommended for high speed turning of grey cast-iron (I) (V) K10 (K05 K20) V-coated cemented carbide consisting of a thick, smooth wear resistant coating and a very hard substrate. Recommended for high speed turning oodular cast-iron (NI) () K15 (K10 K25) V-coated cemented carbide consisting of a smooth wear resistant coating and a hard substrate capable of withtanding demanding interrupted cuts. Recommended as first choice for roughing of all cast-irons at low to medium cutting speeds. omplementary grades 620 () K01 (K01 K05) "Pure" l2o3-based ceramic. Recommended for high speed finishing of grey cast irons under stable and dry conditions. T5005 (T) K05 (K01 K05) n uncoated cermet for super-finishing of nodular cast-iron. The grade is the most wear- and plastic deformation-resistant cermet. It has very good resistance to built-up edge formation. When high-quality surfaces, small cutting forces and/or close tolreances are required. eed/ O cross-section smaller than 0.35 square-mm. T5015 (T) K05 (K01 K10) n uncoated cermet grade witcellent resistance to built-up-edge and plastic deformation. or finishing oodular cast irons when high surface quality, close tolerances and/or low cutting forces are required. x a p < 0.35 mm () K15 (K05 K25) V-coated carbide grade for finishing to roughing of grey and nodular cast irons at high cutting speeds. Is able to withstand high temperatures without sacrificing edge security. 13 (W) K20 (K10 K30) Uncoated carbide grade. ombines good abrasive wear resistance and toughness. or moderate to low speeds and high feeds in cast iron. 68

3 NRL TURNIN Turning M Stainless steel NSI asic grades omplementary grades Toughness Wear resistance K ast iron NSI asic grades omplementary grades 620 T 5005 T Toughness Wear resistance ardmetals: W Uncoated hardmetal containing primarily tungsten carbide (W). T Uncoated hardmetal, also called cermet, containing primarily titanium carbides (TI) or titanium nitrides (TIN) or both. ardmetals as above, but coated. eramics: Oxide ceramics containing primarily aluminium oxide (l2o3). M Mixed ceramics based on aluminium oxide (l2o3) but containing components other than oxides. eramics as above, but coated. The position and form of the grade symbols indicate the suitable field of application. entre of the field of application. } Recommended field of application. 69

4 NRL TURNIN N Non ferrous metals asic grades 10 (W) N15 (N01 N25) Uncoated carbide grade. ombines excellent abrasive wear resistance and edge sharpness. or rough to finish turning of luminum alloys () N10 (N01 N15) diamond-coated grade for finishing to roughing of aluminium, magnesium, copper, brass, plastics etc. The diamond-coating gives excellent wear-resistance and less built-up-edge, which results in high surface quality. 10 (P) N05 (N01 N10) polycrystalline diamond grade for finishing and semi-finishing oon-ferrous and nonmetallic materials. ives long tool life, clean cut and good finish. omplementary grades 13 (W) N15 (N05 N25) Uncoated carbide grade. ombines good abrasive wear resistance and toughness for medium to rough turning of aluminium alloys. S eat resistant and super alloys asic grades 670 () S15 (S05 S25) silicon carbide whisker reinforced aluminium oxide based ceramic witcellent bulk toughness. Primarily recommended for heat resistant alloys under unfavourable conditions. S05 () S05 (S05 S15) V-coated carbide. or high speed finishing in RS, or long cuts at lower speeds. or applications where notch is not a significant problem ie round inserts, small entry angle and softer materials, this grade can also be used in roughing applications () S15 (S05 S20) PV-coated carbide. The combination of a hard fine grain substrate with good plastic deformation resistance and a coating with high wear resistance at high temperatures, makes this grade most suitable for Ni, e or o-based heat resistant super alloys () S15 (S10 S25) PV-coated micro-grain carbide. Recommended for heat resistant super alloys and Titanium alloys at low speeds. reat resistance to thermal shock and notch wear makes it suitable for long cuts or intermittent cuts. omplementary grades 650 () S05 (S01 S10) Mixed l 2 -based ceramic. ould be used in semi-finishing operations of high-temp alloys in applications with low demand on edge security. 10 (W) S10 (S01 S15) Uncoated carbide grade. ombines excellent abrasive wear resistance and edge sharpness. or finish turning of heat resistant steels and titanium alloys 10 (W) S10 (S01 S20) Uncoated carbide grade. ombines good abrasive wear resistance and toughness for medium to rough turning of heat resistant steels and titanium alloys. 10 (W) S15 (S15 S30) Uncoated fine-grain carbide grade. Recommended for heat resistant super alloys or Titanium alloys at very low speeds. reat resistance to thermal shock and notch wear makes it suitable for long cuts or intermittent cuts. 13 (W) S15 (S10 S30) Uncoated carbide grade. ombines good abrasive wear resistance and toughness for medium to rough turning of heat resistant steels and Titanium alloys. ardened materials asic grades 7015(N) 15 (01 20) high-performance, low-content N grade. irst choice for continuous and light, interrupted cuts at high cutting speeds in case-hardened steel. 7020/20(N) 20 (10 25) igh performance ubic oron Nitride grade. irst choice for continuous and light interrupted cuts in hardened steel () 05 (01 10) mixed aluminium oxide based ceramic grade with good thermal properties and wear resistance. Primarily recommended for light continuous finishing. 670 () 10 (05 15) silicon carbide whisker reinforced aluminium oxide based ceramic witcellent bulk toughness. Recommended for hard part turning under unfavourable conditions. 13 (W) 20 (15 25) Uncoated carbide grade. ombines good abrasive wear resistance and toughness for turning of hardened materials at low speeds. 7050/50 (N) 25 (20 30) n extremely hard ubic oron Nitride rade. igh edge toughness and good wear resistance makes it first choice for interrupted cuts in hardened steel () 15 (05 25) V-coated carbide grade for finishing to roughing of hardened materials. Is able to withstand high temperatures without sacrifying edge security. 70

5 NRL TURNIN Turning Letter symbols specifying the designation of hard cutting materials: ardmetals: W Uncoated hardmetal containing primarily tungsten carbide (W). T Uncoated hardmetal, also called cermet, containing primarily titanium carbides (TI) or titanium nitrides (TIN) or both. ardmetals as above, but coated. N Non-ferrous metals NSI asic grades omplementary grades 13 Toughness Wear resistance eramics: Oxide ceramics containing primarily aluminium oxide (l 2 ). M Mixed ceramics based on aluminium oxide (l 2 ) but containing components other than oxides. N Nitride ceramics containing primarily silicon nitride (Si3N4). eramics as above, but coated. iamond: P Polycrystalline diamond 1 ). oron nitride: N Polycrystalline boron nitride 1 ). eat resistant and super alloys S Ni-based NSI asic grades 670 S omplementary grades Toughness Wear resistance 1 ) Polycrystalline diamond and polycrystalline boron nitride are also named superhard cutting materials. S Ti-based Toughness Wear resistance The position and form of the grade symbols indicate the suitable field of application. entre of the field of application. } Recommended field of application. ardened materials NSI asic grades omplementary grades Toughness Wear resistance 71

6 rades P M P = Steel M = Stainless steel Overview of grades -P -M -K -N -S - Stable K N S K = ast iron N = luminum and non-ferrous materials S = eat resistant super alloys = ardened materials or first choice recommended grade and geometry used on material and type of application. Wear resistance Toughness T S onditions Unstable Mixed material group inserts Material group P M K K P M P S M eometry -W -WM Recommended grade 4025, , WR QM -QR 4025, , PR ouble sided 4025, MR Single sided 4025, , 2015 KNMX-71 KNUX 4025,

7 OT RI () V = hemical Vapour eposition coated grades 2015, 2025, 2135, 235, 3205, 3210, 3215, 3115, 4005, 4015, 4025, 4035, S05, and PV = Physical Vapour eposition coated grades 1005, 1020, 1025, 1525, 2035, 2145 and TilN l 2 l 2 Ti (,N) Ti (,N) 1005 (M15, S15) 1005 has a 4 µm PV coating of TilN-. This tough and wear resistant coating, in combination with a very hard and fine grained substrate, provides the needed properties to have sharp cutting edges and a high security against chip hammering. grade for close tolerances and excellent surface finish for finishing in RS and stainless steels (M15, P25) 2015 has a substrate designed for high cutting speeds. tough gradient zone close to the surface provides excellent line security. The multi-layer coating of 5.5 microns gives very good heat and wear protection and reduces friction and hence the formation of built-up edges (M30, P35, S30) 2135 is based on a tough substrate with very good resistance to thermal and mechanical shocks. On top of that is a thin 4 µm V - l2o3- coating, which provides very good flank wear resistance and reduces friction and hence the formation of built-up-edges. This is a grade with very good bulk and edgeline toughness. To be used at low to medium cutting speeds. l 2 Ti (,N) TilN 1020 (M20, P25) 1020 has a 1-2 µm PV coating on top of a very fine grained substrate developed for high quality threading. xcellent performance in all three material groups P, M and K (M25, P35) 2025 consists of a 5.5 µm V - l2o3- coating on a substrate which features excellent resistance to both mechanical and thermal shock. This gives excellent adhesion with high wear resistance to crater wear and plastic deformation at high temperatures. lso reduces friction and hence the formation of built-up-edges (M40, P45, S40) 2145 has an even tougher substrate than 2135 but still with a very good resistance to thermal and mechanical shocks. The tough and wear resistant coating, a 4 µm PV coating of TilN-, in combination with the very tough substrate makes 2145 the perfect choice for cut-off to centre and other applications with an extreme demand on toughness. To be used at low cutting speeds. TilN 1025 (M15, S15, P25) 1025 has a 4 µm PV coating of TilN-. This tough and wear resistant coating, in combination with a very fine grained substrate, provides the needed properties to have sharp cutting edges and a high security against chip hammering. grade for close tolerances and excellent surface finish for finishing in stainless steels. TilN 2035 (M25) 2035 has a 4 µm PV coating of TilN-, which provides very good wear resistance, toughness and reduces friction, hence the formation of built up edges. The good resistance to both mechanical and thermal shock of 2025 is preserved in grade with maximum edge toughness, ideal for both intermittent machining at high speeds in the M25 area and for heavy roughing where cutting speeds are limited. Ti (,N) Ti 235 (M40, P45) 235 has a very tough substrate, which provides and extremely good edge scurity. It is coated with a 2.5 µm V Ti-- Ti for added wear resistance and lower friction. 235 is very good in demanding roughing applications, e.g. interrupted cuts and low speeds. Works well in steel and stainless steel at low to moderate speeds. 73

8 OT RI () l 2 l 2 Ti (,N) Ti (,N) l 2 Ti (,N) 3205 (K05, P05) 3205 is a V-coated cemented carbide consisting of a 15 microns thick, smooth wear resistant coating and a very hard substrate. This grade is designed to withstand high temperatures without being deformed. It is optimized for high speed turning of grey cast-iron (I). 3115, 3020 (K15, P15) ased on a hard substrate with a good resistance to plastic deformation due to high hot hardness. The top performance V coating of and l2o3 provides an excellent flank wear resistance. Ideal for grooving and turning operations in cast iron with high cutting speeds. lso for cut-off under stable conditions. l (P35, M25) 4035 has a coating of the same type as The coating brings wear resistance to the grade. The substrate is tougher than 4025 and has a gradient zone close to the surface is a good choice in applications with demands on both toughness and resistance to plastic deformation. It works very well in interrupted cuts. secure grade for high productive applications in the P35 area, the tough steelworker. lso suitable for stainless steel machining in the M25 area when extra wear resistance is sought (K10, P10) 3210 is a V-coated cemented carbide consisting of a thick, smooth wear resistant coating and a very hard substrate. It is optimized for high speed turning oodular cast-iron (NI) l 2 Ti (,N) Ti (,N) 4005 (P05) 4005 has a very thick, 18 microns, V coating (-l2o3-). Under the coating is a hard substrate with a thin gradient zone giving extra edge-line toughness. This provides the grade witcellent resistance to crater wear and plastic deformation. very good choice when machining dry, long engagement times or at high cutting speeds. Suitable for medium to roughing of steel. l 2 Ti (,N) 4015 (P15, K15) 4015 has a thick, 14 µm, V - l2o3- coating. The coating has an extremely good wear resistance and is golden coloured for easy wear detection. Under the coating there is a hard substrate with a thin gradient zone close to the surface. ecause of this, the grade can withstand high cutting temperatures and still have a good edgeline security. This makes 4015 ideal for high cutting speeds and dry machining in the P15 area. top performing grade. lso a good choice for machining of grey and nodular cast iron. TilN 4125 (P30, M25, K30, S25) 4125 has a 4 µm PV coating of TilN-. This tough and wear resistant coating, in combination with a very fine grained substrate, makes the grade both hard and tough. true all-round grade that works good in most types of materials and operations. l 2 Ti (,N) l 2 Ti (,N) 3215 (K15, P10) 3215 is a V-coated cemented carbide consisting of a smooth, wear resistant coating and a hard substrate. This grade is capable of withstanding demanding interrupted cuts. It is recommended as the general choice for roughing of all types of cast-iron at low to medium cutting speeds. l 2 Ti (,N) 4025 (P25, M15) 4025 has a thick layer of l2o3 on top of a medium sized layer. thin outer layer gives the grade a yellow colour for easy wear detection. The total thickness of this V coating is approx. 12 µm. The substrate is rather hard but has a large gradient zone that brings toughness and better edgeline behaviour to the grade. The combination of a thick wear resistant coating and a hard substrate witcellent edge security has made 4025 very popular. It works extremely well in P25 applications but also in stainless steels and cast iron. Used in many different operations. S05 (S05) S05 has a thin 4 µm V - l2o3- coating on top of a very hard and finegrain substrate. This grade is optimized for finishing cuts in RS. To be used in conditions where notch is not a significant problem, i.e. shallow depths of cuts, round inserts, small entry angle and softer materials. 74

9 RMT Uncoated cermet (T) UNOT RI (W) Turning T5005 (P05, K05) T5005 is an uncoated cermet for superfinishing of steel. The substrate is very hard and wear resistant. It has high resistance against plastic deformation and built-up edge formation. Suitable for high-quality surfaces, close tolerances and small cutting forces. eed/ O cross-section smaller than 0.35 square-mm. 10 (N15, S10) 10 is an uncoated fine-grain carbide grade. ombines excellent abrasive wear resistance and edge sharpness. or rough to finish turning of aluminum alloys. lso suitable for finish turning of RS and Titanium alloys. 13 (K20, S15, N15) 13 is an uncoated carbide grade. ombines good abrasive wear resistance and toughness. or rough to finish turning of heat resistant alloys, Titanium alloys, cast irons and luminum alloys. T5015 (P05, K05) T5015 is an uncoated titanium based cemented carbide, more frequently called a cermet. Titanium instead of tungsten improves the chemical stability and makes T5015 ideal for machining of smearing materials. T5015 is a hard wear resistant grade with good resistance to plastic deformation. pure cobalt binder adds toughness and security to the substrate. Keeping the grade uncoated ensures that a sharp edge is maintained throughout the tool life. This means good surface finish and low cutting forces. finishing grade for high quatlity surfaces at both high and low cutting speeds. 10 (S10) 10 is an uncoated carbide grade. ombines good abrasive wear resistance and toughness for medium to rough turning of heat resistant steels and Titanium alloys. oated cermet () Ti (,N) 1525 (P15, M10) 1525 is a PV coated cermet for finishing and semi-finishing. The substrate is of the same kind as T5015 but tougher. The 3 µm PV coating of - adds wear resistance and resistance to plastic deformation. The coating is chosen due to superior compatibility with the substrate, minimizing the risk of flaking is our toughest available cermet for high process security and good surface finish. 10 (S15) 10 is an uncoated fine-grain carbide grade. Recommended for heat resistant super alloys or Titanium alloys at very low speeds. reat resistance to thermal shock and notch wear makes it suitable for long or intermittent cuts. 75

10 RMIS Pure ceramic (): Silicon nitride based ceramic (N): oated ceramic (): l (K01) 620 is a pure oxide ceramic grade based on alumina with a small addition of zirconium oxide to give it improved toughness. 620 is designed for high cutting speed applications in cast iron and steel under stable conditions. oolant should not be used (K10) 6090 is a pure silicon nitride ceramic grade well suited for roughing to finishing of grey cast iron at high speeds under stable conditions (K10) 1690 is a silicon nitride substrate with a 1 µm thin l2o3 - coating. The properties of 1690 make it highly recommendable for light roughing, medium and finishing applications in cast iron. 670 (S15, 10) 670 is a silicon carbide "whisker" reinforced ceramic grade, where the whiskers are randomly orientated within the host material. It is particularly well suited for high speed machining of heat resistant super alloys and hardened materials where demands are high for security or toughness (05) 6050 is a mixed ceramic grade based on alumina with an addition of titanium carbide. The high hot-hardness, the good level of toughness makes the grade suitable as first choice for case-hardened steel (50 65 Rc) in applications with good stability or with light interrupted cuts. Mixed ceramic (M): 650 (K01, 05, S05) 650 is a mixed ceramic grade based on alumina with an addition of titanium carbide. It is primarily recommended for finishing operations in cast iron, hardened steel, hardened cast iron and heat resistant super alloys where the combination of wear resistant and good thermal properties is required. 76

11 ubic oron Nitride IMON Turning N (N) Polycrystalline iamond (P) 20 (01) 20 is a cubic oron Nitride (cn) grade based on cn with an addition of titanium nitride. Typically, this grade consists of one cn tip, which is brazed onto a carbide carrier. grade with high chemical resistance as well as high wear resistance for finishing operations in hardened steel and hardened cast iron. 50 (K05, 05) 50 is a pure cubic oron Nitride (cn) grade with very high abrasive wear resistance and toughness. Typically, this grade consists of one cn tip, which is brazed onto a carbide carrier. 50 is primarily recommended for cast iron and hardened materials in tough conditions. 10 (N05) 10. a polycrystalline diamond grade, is composed of fine to medium-fine grain crystals with an average diamerer of 7 µm. It is recommended for finishing and semi-finishing oon-ferrous and non-metallic materials (15) 7015 is a cubic boron nitride (N) grade based on N with an addition of a fine-grain titanium binder. The grade is designed for high-speed finishing of case-hardened steels (58 65 Rc) where high-quality surfaces are required. V diamond coated carbide () iamond 7020 (01) 7020 is a cubic oron Nitride (cn) grade based on cn with an addition of titanium nitride. or superior bonding and security, the cn material is sintered (not brazed) onto each corner of the carbide carrier, hence the name multi-corner insert. The insert also has a PV coating for easy wear detection. grade with high chemical resistance as well as high wear resistance for finishing operations in hardened steel and hardened cast iron (K05, 05) 7050 is a pure cubic oron Nitride (cn) grade with very high abrasive wear resistance and toughness. or superior bonding and security, the cn material is sintered (not brazed) onto each corner of the carbide carrier, hence the name multi-corner insert. The insert also has a PV coating for easy wear detection is primarily recommended for cast iron and hardened materials in tough conditions (N10) 1810 is a V diamond coated insert based on a specially adapted substrate. The extremely wear resistant coating of 6 8 µm high purity dimond provides excellent properties for the machining oon-ferrous alloys. 77

12 utting data 15 min T c min eed and speed The following contain recommended cutting data for machining the more common materials. In the tables, cutting speeds for different materials and feeds are given. The values are calculated on the basis of a tool life of 15 minutes and should be regarded as starting values. Selecting feed In rough turning operations power and stability of the machine and the chip forming ability are often limiting factors. The most economical choice of cutting data, i.e., maximum metal removal rate, is obtained with a combination of high feed and moderate cutting speed with limiting factors taken into consideration. The power available in the machine can sometimes be too low. In such cases it is necessary to reduce the cutting speed to suit. When selecting feeds for finishing operations, surface finish, tolerance and chipbreaking requirements should be taken into consideration. Surface finish is determined by the combination of feed rate and insert nose radius, as well as the workpiece stability, clamping and the overall condition of the machine. hipbreaking is determined by the selection of insert geometry. The Wiper geometry inserts should be an obvious candidate for finishing operations which will affect the choice of feeds. Selecting cutting speed utting speeds are given for a specific material hardness and for an entering angle κ r = 90. If the material being machined 105 Q z cm 3 /min Q z = metal removal: cm 3 /min v c = cutting speed: = feed: mm/r v c = mm/r differs in hardness from those values, the recommended cutting speed should be multiplied by a factor obtained from the table. If the entering angle is less than 90, the cutting speed may be increased with maintained tool life. ifference in hardness Reduced hardness Increased hardness M No. ardness rinell () M No. ardness Rockwell (R)

13 ommon exceptions v c 220 = 0.91 x v c 180 = 0.91 x 425 = ifference in hardness If your material has another hardness than 180, you should adjust cutting speed (v c ) according to the table. ere is the same example as above but the hardness is = +40 The table gives a correction factor of Values for standard corner radius Values for Wiper radius 2 specified Ra value for the surface finish The example gives you a R a value of around 1.25 µm. Nose radius 0.8 and fn = 0.2. See the tables for surface finish. If you need R a 0.7. you should adjust the feed rate according to the tables. R a 0.7 gives Wiper inserts Wiper inserts give a much better surface finish at the same feed rates. Increased feed rates will give the same surface finish. ( R a 1.25 gives 0.35.) lways consider Wiper inserts as first choice if possible. 3 To adjust the cutting speeds for a longer tool life Most cutting speeds are suitable to achieve a tool life of 15 minutes. If you would like to adjust the cutting speeds for a longer tool life, see below. ccording to 1 the cutting speed chosen is 387. tool life of 30 minutes gives you 387 x 0.87 = 337. Tool life (min) orrection factor

14 utting speed recommendations The recommendations are valid for use with cutting fluid. M No. Material Specific cutting force k c 0.4 ardness rinell WR RSISTN T5005 T , mm feed, P 01.1 Steel Unalloyed steel Low-alloy steel, (alloying elements 5%) igh-alloy steel (alloying elements >5%) Steel castings = % = % = % Non-hardened all bearing steel ardened and tempered ardened and tempered nnealed ardened tool steel Unalloyed Low-alloy (alloying elements 5%) igh-alloy, alloying elements >5%) N/mm utting speed, v c M No. Material Specific cutting force k c 0.4 ardness rinell WR RSISTN , mm feed, M Stainless steel ars/forged erritic/martensitic Stainless steel ars/forged ustenitic Non-hardened P-hardened ardened ustenitic P-hardened Super austenitic N/mm utting speed, v c Stainless steel Stainless steel ars/forged ustenitic-ferritic (uplex) Stainless steel ast erritic/martensitic Stainless steel ast ustenitic Non-weldable Weldable Non-hardened P-hardened ardened ustenitic P-hardened Super austenitic 0.05% <0.05% M No. Stainless steel ast ustenitic-ferritic (uplex) Material Non-weldable Weldable 0.05% <0.05% Specific cutting force k c 0.4 ardness rinell WR RSISTN 7050/ , mm feed, K Malleable cast iron rey cast iron erritic (short chipping) Pearlitic (long chipping) Low tensile strength igh tensile strength N/mm utting speed, v c ast iron Nodular S iron erritic Pearlitic Martensitic

15 utting speed, v c , mm feed, , mm feed, utting speed, v c TOUNSS TOUNSS TOUNSS utting speed, v c , mm feed, T T

16 utting speed recommendations The recommendations are valid for use with cutting fluid. M No. Material Specific cutting force k c 0.4 ardness rinell WR RSISTN , mm feed, N luminium alloys Wrought or wrought and coldworked, non-aging Wrought or wrought and aged N/mm utting speed, v c 2000 ( ) 1) 2000 ( ) 1) 2000 ( ) 1) 2000 ( ) 1) 2000 ( ) 1) 2000 ( ) 1) Non-ferrous metals luminium alloys luminium alloys opper and copper alloys ast, non-aging ast or cast and aged ast, 1315% Si ast, 1622% Si ree cutting alloys, 1% Pb rass, leaded bronzes, 1% Pb ronze and non-leadad copper incl. electrolytic copper ( ) 1) 2000 ( ) 1) 1550 ( ) 1) 770 ( ) 1) 500 ( ) 1) 500 ( ) 1) 300 ( ) 1) 2000 ( ) 1) 2000 ( ) 1) 770 ( ) 1) 510 ( ) 1) 500 ( ) 1) 500 ( ) 1) 300 ( ) 1) 2000 ( ) 1) 2000 ( ) 1) (560 55) 1) (375 38) 1) 500 ( ) 1) 500 ( ) 1) 300 ( ) 1) M No. Material Specific cutting force k c 0.4 ardness rinell WR RSISTN 650, mm feed, S eat resistant material ardened material M No 04.1 eat resistant super alloys Iron base nnealed or solution treated ged or solution treated and aged Nickel base obalt base Titanium alloys 2) ard steel xtra hard steel hilled cast iron nnealed or solution treated ged or solution treated and aged ast or cast and aged nnealed or solution treated Solution treated and aged ast or cast and aged ommercial pure (99.5% Ti) α, near α and α+β alloys, annealed α+β alloys in aged cond., β alloys, annealed or aged Material ardened and tempered ardened and tempered 10.1 ast or cast and aged 1) The cutting speeds, shown in the table, are valid for all feeds within the feed range. 2) 4560 entering angle, positive cutting geometry and coolant should be used. 3) Rm = ultimate tensile strength measured in MPa Non-ferrous materials hoosing polycrystalline diamond tipped inserts (P) or carbide inserts? The P grade 10 and diamond coated grade 1810 could be a useful alternative to cemented carbide for finishing and semi-finishing in non-ferrous metals and non-metallic materials. N/mm 2 Specific cutting force k c 0.4 Rm 3) ardness rinell R R utting speed, v c WR RSISTN N/mm 2 utting speed, v c / /50, mm feed, Use diamond for exceptionally long tool life excellent surface finish machining economy stable conditions Use cemented carbide for chip control edge security low cost per edge setting up oew jobs unstable conditions 82

17 TOUNSS 13, mm feed, utting speed, v c 1900 ( ) 1) 1900 ( ) 1) 1900 ( ) 1) 1900 ( ) 1) 400 ( ) 1) 250 ( ) 1) 450 ( ) 1) 450 ( ) 1) 270 ( ) 1) TOUNSS S , mm feed, utting speed, v c TOUNSS , mm feed, utting speed, v c N in cast iron, hardened and heat resistant materials ubic boron nitride grades 7020, 7015, 20, 7050 and 50 N inserts can increase productivity in many difficult metal cutting operations up to 100 times better than carbide or ceramics in terms of longer tool life and/or higher metal removal rate. N is recommended primarily for finishing operations: 7050/50 for cast iron and heat resistant materials. 7015/7020/20 for continuous and light interrupted cuts in hardened parts. 83

18 eneral cutting data recommendations for cast iron, hardened steels and heat resistant super alloys (advanced tool materials) The following tables show recommended grade and cutting data for each application area. The bars indicate the general working areas and the darker areas the most common ranges. The lines in the bars are recommended starting values. The cutting data for cast iron machining in the table below are given for continuous cuts. or interrupted cuts reduce the feed rate and the depth of cut. ST IRON MININ K utting tool material bility to take interrupted cuts utting speed, v c eed, mm/r epth of cut, a p mm M 1) Pure ceramic NO 650 Mixed ceramic NO 6050 Mixed ceramic YS 6090 Silicon nitride YS 1690 oated silicon nitride YS ast iron 7050 ubic boron nitride 50 ubic boron nitride YS YS 2) 2) Pure ceramic NO 650 Mixed ceramic 690 Silicon nitride 1690 oated silicon nitride NO YS YS 1) oromant Material lassification M 07 = Malleable cast iron M 08 = rey cast iron M 09 = Nodular cast iron 2) igh cutting speeds are recommended, up to Use the same cutting speeds for cast iron with low, max 5%, ferrite contents 84

19 NON RROUS MTLS N Non-ferrous metals Material luminium alloys utting tool material 2) 10 utting speed, v c eed, mm/r 1) M luminium alloys luminium alloys opper and copper alloys T RSISTNT SUPR LLOYS S nnealed or solution treated utting speed, v c eed, mm/r inishing / M 1) Ni-based Light roughing Roughing Material utting tool material 2) eat resistant super alloys ged or solution treated and aged ast or cast and aged o-based nnealed or solution treated Solution treated and aged v c ast or cast and aged ) oromant Material lassification 2) inishing: a p = mm = mm/r Medium: a p = mm = mm/r Roughing: a p = 2-5 mm = mm/r These cutting data are valid for ceramic cutting materials. 85

20 R PRT TURNIN RN STL ard part turning utting tool material ubic boron nitride 670 Whisker reinforced ceramic ubic boron nitride 7050 ubic boron nitride Operation INISIN ontinuous cuts INISIN Interrupted cuts INISIN Interrupted cuts INISIN Interrupted cuts utting speed, v c eed, mm/r epth of cut, a p mm M 1) INISIN Mixed ceramic ontinuous cuts ubic boron nitride INISIN ontinuous cuts RN ST IRON utting tool material omponent utting speed, v c eed, mm/r epth of cut, a p mm M 1) oated silicon nitride 6090 Silicon nitride NW ROLLS With skin ST IRON ardened cast iron 670 Whisker reinforced ceramic 670 Whisker reinforced ceramic 650 Mixed ceramic NW ROLLS Without skin v c mm/r a p mm ubic boron nitride RWORK O ROLLS eneral v c mm/r a p mm Whisker reinforced ceramic RWORK O ROLLS With cracks 1) oromant Material lassification Note: or larger rolls use lower cutting speed and higher feed. or smaller rolls use higher cutting speed and lower feed. 86

21 without coolant no problem for modern inserts Turning ry turning is highly feasible and there are many successful applications in operation. Turning and milling are the easiest machining operations to perform without coolant and there is a requirment from industry in general to question the use of coolants. Major considerations, however, are the cost of buying, using, handling and disposal of coolants some 15% of the manufacturing cost of a typical component, as well as the environment. Modern indexable inserts are fully capable of dry machining. The development of tool materials, especially that of coated cemented carbide grades, has provided inserts that stand up to higher machining temperatures than before by having more resistance to plastic deformation and thermal cracking. In many modern N-machine operations with high speeds and feeds, coolants are insufficient or wrongly directed anyway to have any real effect and in some cases cause negative thermal variations. can easily be tested. In some cases minimum quantity lubrication might be an alternative as some operations such as threading, reaming, boring and parting and grooving are more sensitive. When successfully applied, dry machining has provided: - higher productivity - improved chip control - lower machining costs - improved chip handling - improved environment hecklist for application : - assess the component, operations and machinery as regards the effects of dry machining - optimize each machining operation, especially as regards tools, cutting data, economic tool-life and chip disposal - test effects of dry machining on component quality, accuracy and surface finish higher cutting zone temperature is in many instances a positive factor if the insert grade is correctly chosen. Many of the modern coated grades have been developed with dry machining in mind. uilt up edge formation on the cutting edge and poor chip formation are examples of negative consequences of lower temperatures. Some tool materials and operations are negatively affected by thermal oscillations. ry machining, however, is not suitable for all applications. ertain component materials and operations need coolant to maintain the temperature at a suitalble level, such as in machining RS materials, and for some drilling and boring operations to ensure chip evacuation. ompressed air may in some cases be an alternative. hips normally contain excessive heat which may raise the temperature in the machine. Operations, materials, component, quality demands and machinery should be carefully assessed to see what gains can be had from turning off the coolant tap. It is not normally necessary to re-adjust component measuring to compensate for the effects of dry machining but this 87

22 If problems should occur Problem: ause: Remedy: xcessive flank and notch wear a. Rapid flank wear causing poor surface finish or out of tolerance. b/c. Notch wear causing poor surface finish and risk of edge breakage. a. utting speed too high or insufficient wear resistance. b/c. Oxidation Reduce the cutting speed. Select a more wear resistant grade. Select an l2o3 coated grade. or work hardening materials select a smaller entering angle or a more wear resistant grade. b/c. ttrition Reduce the cutting speed. (When machining heat resistant material with ceramics increase cutting speed.) c. Oxidation Select a cermet grade rater wear xcessive crater wear causing a weakened edge. utting edge breakthrough on the training edge causes poor surface finish. iffusion wear due to too high cutting temperatures on the rake face. Select an l2o3 coated grade. Select a positive insert geometry. irst reduce the speed to obtain a lower temperature, then reduce the feed. Plastic deformation Plastic deformation dge depression or flank impression Leading to poor chip control and poor surface finish. Risk of excesive flank wear leading to insert breakage utting temperature too high combined with a high pressure. Select a harder grade with better resistance to plasic deformation. dge depression Reduce speed lank impression Reduce feed uilt-up edge (.U..) uilt-up edge causing poor surface finish and cutting edge frittering when the.u.. is torn away. Workpiece material is welded to the insert due to: Low cutting speed. Increase cutting speed. Negative cutting geometry. Select a positive geometry. Problem : urling of long chips Possible remedy : Increase feed and/or O, select a smaller nose radius 88

23 Problem: ause: Remedy: hip hammering The part of the cutting edge not in cut is damaged through chip hammering. oth the top side and the support for the insert can be damaged. The chips are deflected against the cutting edge. hange the feed. Select an alternative insert geometry. rittering Small cutting edge fractures (frittering) causing poor surface finish and excessive flank wear. rade too brittle. Insert geometry too weak. Select tougher grade. Select an insert with a stronger geometry (bigger chamfer for ceramic inserts). uilt-up edge Increase cutting speed or select a positive geometry. Reduce feed at beginning of cut. Thermal cracks Small cracks perpendicular to the cutting edge causing frittering and poor surface finish. Thermal cracks due to temperature variations caused by: - Intermittent machining. Select a tougher grade with better resistance to thermal shocks. - Varying coolant supply. oolant should be applied copiously or not at all. Insert breakage Insert breakage that damages not only the insert but also the shim and workpiece. rade too brittle. xcessive load on the insert. Select a tougher grade. Reduce the feed and/or the depth of cut. Insert geometry too weak. Select a stronger geometry, preferably a single sided insert. Insert size too small. Select a thicker/larger insert. Slice fracture eramics xcessive tool pressure. Reduce the feed. Select a tougher grade. Select an insert with smaller chamfer. Problem : Vibrations Possible remedy : Reduce cutting speed, increase feed, reduce O, select a smaller nose radius, select a positive geometry. 89