PR1225. The MEGACOAT Series. Effective for Stainless Steel. Ideal for small part machining demanding high quality and stable cutting

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1 MEGACOAT The MEGACOAT Series New PVD Coating for Small Tools Effective for Stainless Steel Ideal for small part machining demanding high quality and stable cutting

2 The MEGACOAT Series High quality small tool grade MEGACOAT Advantages With superior anti-oxidation resistance and an extra hard coating, covers a wide application range. Improved coating adherence provides increased stability and longer tool life. New thin coating technology greatly reduces adhesion to the work piece providing more effective machining in stainless steel. New sharp-edge series chipbreakers provide stable cutting and superior chip evacuation. Hardness (GPa) TiCN TiN TiAlN MEGACOAT Oxidation onset temperature( C) Effective for Stainless Steel Edge Quality Comparison <Sharp edge and a flat surface> Coating Adhesion Comparison <Superior Coating Adhesion> X300 X1000 Competitor A <Rough edge and uneven surface> X500 (End) Low Middle High work load Competitor B <Deteriorating Surface Coating> X300 X1000 X500 (End) Low Middle High work load Application Range High speed [150m/min] PR1025 Recommended Cutting Conditions Workpiece material Classification Vc:m/min Carbon Steel / Alloy Steel 50~80~120 Medium speed [100m/min] MEGACOAT Stainless Steel 50~80~120 :Light Interruption / 1st Choice :Light Interruption / 2nd Choice Low speed [50m/min] PR930 Continuous Light interruption Heavy interruption Application 1

3 Sharp edge chipbreaker 3 New chipbreaker series delivers excellent chip control in wide range of cutting. Excellent for use when high precision cutting is required. 2 1 GQ GF The mirror polished insert provides improved adhesion resistance and surface finish. CF Feed Rate f(mm/rev) Applicable to both small and large D.O.C GQ Chipbreaker Applicable to a wide D.O.C. range (ap=0.8~3mm) Chip Evacuation Comparison [SUS304 Vc=80m/min Wet DCGT11T302type] GQ Chipbreaker Competitor C Low cutting force design with small chipbreaker gap Achieves chip control at low cutting depths with a dot that overhangs to the edge Unstable chips Feed Rate f(mm/rev) Feed Rate f(mm/rev) Application range Application range Enables cutting over a wide range of conditions by using the optimum chipbreaker width according to the cutting depth For finishing GF Chipbreaker Applicable D.O.C. range from 0.25 to 1.25mm Chip Evacuation Comparison [S45C(ø10) Vc=100m/min Wet DCGT11T302type] GF Chipbreaker Competitor D High breaker dot apart from ridge line of cutting edge Good heat resistance and chip control in cutting of high D.O.C Unstable chips Increased sharpness through the use of a large rake angle Feed Rate f(mm/rev) Feed Rate f(mm/rev) Dot located close to ridge line of cutting edge on corner Chips fragmented in small pieces in cutting of small D.O.C Application range Application range Applicable to minute D.O.C CF Chipbreaker Specially designed CCGT and WBGT inserts for minute-diameter boring Applicable D.O.C. range from 0.02 to 0.2mm Consistent curled chips t h ro u g h t h e u s e o f special dots Increase sharpness by large rake angle Prevents work piece adhesion and reduces burrs Chip Evacuation Comparison [SUS304 Vc=100m/min Wet CCGT030102type ] CF Chipbreaker Conventional grinding breaker E Feed Rate (mm/rev) Feed Rate (mm/rev) 2

4 Positive Insert Identification System CCGT M F R - U Sharp edge CCGT M F P - GF Sharp edge Use of minus tolerance The actual corner-r of the workpiece may become larger than R0.2mm when machined by the insert whose corner-r is 0.2. In such case, insert with minus tolerance is recommended. Fig. 1 Corner-R on the drawing "" Edge for High Quality and Long Tool Life Recommended for mechatronics, electronics and high precision machined parts Sub-micron accuracy possible High Quality Ground Insert Reduction of micro-chipping at ground edge Less edge build-up Long tool life E-class Turning Insert Thickness Tolerance (Conventional) Corner-R Tolerance (Conventional) Hand Mirror finish on insert top face Accuracy of index position after insert replacement () () Items(Positive) Shape Left-hand shown -Medium Medium cutting CCGT MP-CF MP-CF <0.2 CCGT MP-CF MP-CF <0.2 CCGT MFP-GF MFP-GF <0.2 CCGT 09T301MFP-GF 09T302MFP-GF < T304MFP-GF <0.4 CCGT MFP-GQ MFP-GQ < MFP-GQ <0.4 CCGT 09T301MFP-GQ 09T302MFP-GQ < T304MFP-GQ <0.4 CCGT MF MF MF < MF <0.4 CCGT 09T3005MF 09T301MF 09T302MF <0.2 09T304MF <0.4 /Precision / Precision CCET CCET M$-FSF M$-FSF M$-FSF < M$-FSF < M$-FSF M$-FSF M$-FSF < M$-FSF <0.4 CCGT M$-F M$-F M$-F < M$-F <0.4 CCGT M$-F M$-F M$-F < M$-F <0.4 CCET CCET MF$-USF MF$-USF < MF$-USF <0.2 09T3005MF$-USF 09T301MF$-USF < T302MF$-USF <0.2 CCGT MF$-U MF$-U MF$-U < MF$-U <0.4 CCGT 09T3005MF$-U 09T301MF$-U 09T302MF$-U <0.2 09T304MF$-U <0.4 DCGT MP-CF MP-CF <0.2 DCGT 11T301MP-CF 11T302MP-CF <0.2 DCGT MFP-GF MFP-GF <0.2 DCGT 11T301MFP-GF 11T302MFP-GF < T304MFP-GF <0.4 3

5 Shape Left-hand shown Medium cutting -Medium / Precision / Precision / Precision DCGT MP-CK MP-CK <0.2 DCGT 11T301MP-CK 11T302MP-CK <0.2 DCGT MFP-GQ MFP-GQ < MFP-GQ <0.4 DCGT 11T301MFP-GQ 11T302MFP-GQ < T304MFP-GQ <0.4 DCGT MF MF MF < MF <0.4 DCGT 11T3005MF DCET DCET 11T301MF 11T302MF <0.2 11T304MF < M$-FSF M$-FSF M$-FSF < M$-FSF <0.4 11T3005M$-FSF 11T301M$-FSF 11T302M$-FSF <0.2 11T304M$-FSF <0.4 DCGT M$-F M$-F M$-F < M$-F <0.4 DCGT 11T3005M$-F 11T301M$-F 11T302M$-F <0.2 11T304M$-F <0.4 DCET MF$-USF DCET MF$-USF < MF$-USF <0.2 11T3005MF$-USF 11T301MF$-USF < T302MF$-USF <0.2 DCGT MF$-U MF$-U MF$-U < MF$-U <0.4 DCGT 11T3005MF$-U 11T301MF$-U 11T302MF$-U <0.2 11T304MF$-U <0.4 DCET 11T3005MF$-JSF 11T301MF$-JSF < T302MF$-JSF <0.2 DCGT 11T3005MF$-J 11T301MF$-J 11T302MF$-J <0.2 11T304MF$-J <0.4 TBGT MP-CF < MP-CF <0.2 Shape Left-hand shown -Medium / Precision / Precision / Precision TCGT MF$-U MF$-U < MF$-U <0.2 TCGT MF$-U MF$-U MF$-U < MF$-U <0.4 TPGT TPGT VBET VBGT MP-CF MP-CF < MP-CF MP-CF < M$-FSF M$-FSF < M$-FSF < M$-F M$-F < M$-F <0.2 VBGT M$-Y M$-Y M$-Y < M$-Y < M$-Y <0.8 VBGT M$-Y < M$-Y < M$-Y <0.8 VPGT VPGT VPGT VPGT VPET VPET VPET VPET MP-CF < MP-CF < MFP-GF < MFP-GF < MP-CK MP-CK < MP-CK MP-CK < M$-FSF M$-FSF < M$-FSF M$-FSF < M$-FSF < MF$-USF MF$-USF < MF$-USF MF$-USF < MF$-USF <0.2 WBGT MP$-CF < MP$-CF <0.2 An insert which corner R dimension is shown with inequality sign (Ex:,<0.1,<0.2) indicates minus tolerance of corner R. :Standard 4

6 Items (Small Double Sided Tooling) Shape Right-hand shown -Medium Medium-Roughing -Medium Medium-Roughing With Honing With Honing CNGU MFP-SK MFP-SK <0.2 CNMU E-GK E-GK 0.4 CNGU MFR-F MFR-F MFR-F < MFR-F <0.4 CNGU MFR-U MFR-U MFR-U < MFR-U <0.4 DNGU MFP-SK MFP-SK < MFP-SK <0.4 DNMU E-GK E-GK 0.4 DNGU MFR-F MFR-F MFR-F < MFR-F <0.4 DNGU MFR-U MFR-U MFR-U < MFR-U <0.4 Shape Right-hand shown TNGU MFR-F MFR-F MFR-F < MFR-F <0.4 TNGU MFR-U MFR-U MFR-U < MFR-U <0.4 An insert which corner R dimension is shown with inequality sign (Ex:,<0.1,<0.2) indicates minus tolerance of corner R. :Standard (mm) 4 ap Cutting Range Name Design Advantages - Medium SK Medium- Roughing GK 17 F U SK GK f (mm/rev) Superior chip evacuation and low cutting force for machining steel and stainless steel. Cutting performance comparable to positive insert. Good chip evacuation at wide range through chipbreaker dot and wide chip pocket. 18 Good chip control for finishing to light cutting with low cutting force. U 3 Good chip control at low feed rate and varied ap with low cutting force. F Small Double-Sided Tooling Identification System CNGU M F P -SK Sharp edge Mirror finish on insert top face Use of minus tolerance The actual corner-r of the workpiece may become larger than R0.2mm when machined by the insert whose corner-r is 0.2. In such case, insert with minus tolerance for corner- R is recommended. CNGU M F R - U Sharp edge Hand CNGU M E R - U Fig. 1 Corner-R on the drawing With Honing Hand 5

7 Small Double Sided Tooling SCLN(Without Offset) (External/Facing) Traverse rake angle:-6 Cutting edge inclination angle:-6 F1 B S 9 L2 L1 90 Right-hand Shown h H1 Toolholder Dimension Dimension (mm) H1=h B L1 L2 F1 S SCLNR 1010K-07FF F-07FF K-07FF K-07FF Std.Corner-R Clamp Screw Spare Parts Wrench SB-3080TR LTW-10SS Applicable Insert CNGU CNMU SDLN( Without Offset) (External/Copying) 30 Traverse rake angle:-6 Cutting edge inclination angle:-7 F1 B S 9 L2 L1 90 Right-hand Shown h H1 Toolholder Dimension Dimension (mm) H1=h B L1 L2 F1 S SDLNR 1010K-08FF F-08FF K-08FF K-08FF Std.Corner-R Clamp Screw Spare Parts Wrench SB-3080TR LTW-10SS Applicable Insert DNGU DNMU STLN(Without Offset) (External) Traverse rake angle:-6 Cutting edge inclination angle:-7 B S 9 L2 L1 h H1 F1 90 Right-hand Shown Toolholder Dimension Dimension (mm) H1=h B L1 L2 F1 S STLNR 1010K-09FF F-09FF K-09FF K-09FF Std.Corner-R Clamp Screw Spare Parts Wrench Applicable Insert SB-2570TR LTW-8SS TNGU :Standard 6

8 Case studies SUS304 SUS304 Flange Vc= 85m/min ap=~1.5mm f=0.02~0.05mm/rev Wet DCGT11T302MFP-GQ () ø8.2 ø12.2 Bulb guide Vc= 70~80m/min ap=0.6mm f=0.05~0.07mm/rev Wet DCGT11T302MFP-GF () ø6 ø ,500pcs/edge 1,500pcs/edge Competitor F (3D chipbreaker and PVD coating) 4,000pcs/edge Competitor G (3D chipbreaker and PVD coating) 1,000pcs/edge Compared with competitor E (3D chipbreaker and PVD coating), improves cutting performance by 260%. Compared with competitor F (3D chipbreaker and PVD coating), improves cutting performance by 50%. Evaluation by the user Evaluation by the user SUS440C Clutch axis Vc= 60m/min ap=0.25~1.3mm f=0.03mm/rev Wet CCGT MFR-U () 41.7 ø ~450pcs/edge Competitor H (Grinded chipbreaker and PVD coating) 250~300pcs/edge Because of flat cut, partially interrupted cutting Compared with competitor G (Grinded chipbreaker and PVD coating), improves cutting performance by more than 50%. Evaluation by the user