CA5 Series CA510. New coated grade CA5 series for longer tool life and stable machining. PG Chipbreaker. Insert Grades. CVD Coated Grade for Steel NEW

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1 Insert Grades CA5 Series CA5 Series CVD Coated Grade for Steel New coated grade CA5 series for longer tool life and stable machining High speed and longer tool life Continuous to light interrupted machining General use Heavy interrupted machining and high feed rate Negative type for PG Chipbreaker Positive type for finishing

2 CVD Coated Grade for Steel CA5 Series Wear resistance Conventional Coating P05 Productivity innovation in steel machining Conventional Coating P15 Conventional Coating P25 Stability Conventional Coating P35 by CA5 series and Perfect series Chipbreaker!! Advanced CVD coating new ERA of Kyocera's unique crystal control technology and coating adhesion lead CVD coating to the next level onger tool life Prevent peeling of layer Control Chipping Control -Al2O3 crystal growth for improved wear and fracture resistance Optimized interface improves film adhesion by 40% Higher film strength and fracture resistance by high aspect ratio TiCN TiCN layer Conventional Carbide substrate Conventional "CRIOS Technology" is Kyocera's original CVD coating technology. New carbide substrate Special carbide substrate with deformation resistance at high temperature (10% improved hardness at high temperature) Suitable for high efficiency machining Special carbide substrate Perfect series PP/PQ/PG Chipbreaker Negative type PG Chipbreaker and Positive type are newly available For PG Chipbreaker Positive type Wide chip control range Stable machining with good balance of edge sharpness and strength Prevent chip entangle at high feed rate Good chip control even at low feed rate Negative type (C12 type : Steel / C-type Edge ength=12) PG PQ PP Improve finishing productivity with high reliability Positive type (CPMT09 type : Steel) 2 1 PP

3 High speed and longer tool life Special substrate with thermal deformation resistance along with a thick and tough coating film provide high wear resistance Application: High speed and high efficiency steel machining Wear resistance comparison SCM435 Vc=350m/min, ap=2.0mm, f=0.3mm/rev, Wet VB max (mm) Competitor A Competitor B Competitor C 1st Recommendation General use Special substrate and tough coating film provide high wear and fracture resistance Application: 1st recommendation for steel machining Wear resistance comparison SCM435 Vc=300m/min, ap=2.0mm, f=0.3mm/rev, Wet VB Wear (mm) Competitor Competitor M Competitor D Time (min) Fracture resistance comparison SCM440 (with 4 slots) Vc=300m/min, ap=1.5mm, f=5mm/rev, Wet Competitor N Time (min) Fracture resistance comparison SCM440 (with 4 slots) Vc=300m/min, ap=1.5mm, f=0.3mm/rev, Wet Competitor E Competitor O Competitor F Competitor P ,000 1,500 2,000 2,500 3,000 3,500 4,000 4,500 Number of impacts 0 1,000 2,000 3,000 4,000 5,000 6,000 Number of impacts Continuous to light interrupted machining Special substrate and tough coating film provide thermal deformation and high wear resistance Application: For continuous to light interrupted steel machining (general use) Wear resistance comparison SCM435 Vc=300m/min, ap=2.0mm, f=0.3mm/rev, Wet Heavy interrupted and high feed rate Special tough substrate and tough coating film provide high stability and wear resistance Application: General to heavy interrupted machining (stability oriented) Wear resistance comparison SCM435 Vc=300m/min, ap=1.5mm, f=0.3mm/rev, Wet Competitor G Competitor H Competitor I Competitor Q Competitor R VB max (mm) VB max (mm) Time (min) Time (min) Fracture resistance comparison SCM440 (with 4 slots) Vc=300m/min, ap=1.5mm, f=7mm/rev, Wet Fracture resistance comparison SCM440 (with 4 slots) Vc=100m/min, ap=1.5mm, f=5mm/rev, Wet Conventional J Competitor S Competitor K Competitor T 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 Number of impacts ,000 Number of impacts 2

4 CA5 series High performanc Hot rolled steel S35C (Carbon steel) Automotive parts Vc=500m/min ap=0.7mm f=0.3mm/rev PG Automotive parts Vc=300m/min ap=1.0mm f=0.3mm/rev PQ 100 pcs/edge 200 pcs/edge Competitor U 75pcs/edge Competitor V 150 pcs/edge achieves 1.3 times longer tool life than Competitor U (CVD). achieves 1.3 times longer tool life than Competitor V (CVD). SCM440 (Alloy steel) SCr415H (Alloy steel) Cover Vc=140~150m/min ap=3.0~3.5mm f=0.35~mm/rev PT Gear Vc=380m/min ap=1.5~2.0mm f=0.3~mm/rev PQ 10pcs/edge 430pcs/edge Competitor W 7pcs/edge Competitor X 380pcs/edge achieves 1.4 times longer tool life than Competitor W (CVD). achieves longer tool life than Competitor X (CVD). SS400 (Rolled steel) SCM420 (Alloy steel) Machine part Vc=170m/min ap=mm f=mm/rev PQ Shaft Vc=120m/min ap=2.0mm f=5mm/rev Dry R-ST Competitor Y Molded Chipbreaker 1,400 pcs/edge and more 800-1,000pcs/edge achieves 1.4 times longer tool life than Competitor Y (CVD). Smooth chip control. Competitor Z 10pcs/edge 2pcs/edge achieves 5 times longer tool life than Competitor Z (CVD). 3

5 e of Various case Studies!! Shaft Vc=250m/min ap=3.0mm f=0.3mm/rev PS S45C (Carbon steel) 10pcs/edge Competitor a a b Competitor b 6pcs/edge Instant breakage (PVD Coated) achieves times longer tool life than Competitor a (CVD). Competitor b's PVD carbide could not complete any piece before brakage. Key slot Flange shaft Vc=260~280m/min ap=0.6mm f=0.3~0.5mm/rev PQ Competitor c SCM420 (Alloy steel) 180 pcs/edge 150pcs/edge achieves times longer tool life than Competitor c (CVD). S45C (Carbon steel) SCr420 (Alloy steel) Shaft Vc=100m/min ap=2.0~4.0mm f=mm/rev PS Shaft Vc=90m/min ap=2.0~3.0mm f=0.32mm/rev PS 70 pcs/edge 260 pcs/edge Conventional d 40pcs/edge Conventional e 190pcs/edge achieves 1.7 times longer tool life than Conventional d (CVD). achieves 1.3 times longer tool life than Conventional e (CVD). SCr420H (Alloy steel) 13Cr (Stainless steel) Gear Vc=180m/min ap=2.0mm f=mm/rev CQ Machine parts Vc=100m/min ap=2.0mm f=mm/rev SNMG120412PH 10 pcs/edge 9 pcs/edge Competitor f 3-8 pcs/edge Competitor g 5pcs/edge achieves average 5 times longer tool life than Competitor f (CVD). achieves 1.8 times longer tool life than Competitor g (CVD). Improved machining efficiency by 1.1 times. 4

6 Positive type For Features Improve steel finishing productivity with high reliability Stable machining by resolving problems in boring, such as productivity decrease caused by entangled chip Stable chip control in steel finishing High efficiency and stable tool life in high feed machining, by special edge design with sharpness and strength Highly stable cutting edge design Suitable shape for controlling the edge stress and heat generation Stable performance with superior edge strength CPMT090304PP PP SCM415 (Blind hole) Vc=200m/min, =10mm Wet 100mm 2 (CPMT09 type : Steel) Composite-dot Chipbreaker Multi-dot design with different functions Controls chip's curling condition and flow direction depending on the cutting conditions and workpiece materials 0.5 Stable chip control in any feed rate and workpiece materials PP 1st Dot Small ap 2nd Dot General use range 3rd Dot High feed rate Chip Evacuation Comparison breaks chips and controls entangled chip Competitor h SCM415 Vc=200m/min, ap=0.3mm, f=0.15mm/rev DCMT11T304 Type A20R-SDUCR11-27AE Wet (Internal coolant) No chip remains after machining 50mm Chips remain in the hole 50mm Chip Control Performance covers a wide range of feed rate 50mm f=0.07mm/rev f=0.15mm/rev f=5mm/rev Competitor i 50mm f=0.07mm/rev f=0.15mm/rev f=5mm/rev SCM415 (Blind hole), Wet (Internal coolant) Vc=200m/min,ap=0.3mm, f=0.07-5mm/rev CCMT09T304 Type controls chips stability at high feed rate. Competitor i cannot control chips stability when increase the feed rate. : Good : OK : Bad covers a wide range of workpiece materials 50mm SCM415 SCr420H STKM13A Competitor j SCM415 SCr420H STKM13A 50mm Various work materials, Wet (Internal coolant) Vc=200m/min,ap=0.3mm, f=0mm/rev CCMT09T304 Type 5 controls chips stability from general steel to soft steel. Competitor j generates unstable chips during soft steel machining. : Good : OK : Bad

7 Chipbreaker for steel machining PP / PQ / PG Chipbreaker improves steel machining Negative type For Medium - Perfect Series Stable machining with wide chip control range PG Chipbreaker (C12 type : Steel / C-type Edge ength=12) PQ PP PG Features Stable machining with good balance of edge sharpness and strength Prevent chip entangle at high feed rate. Good chip control even at low feed rate 5 (C12 type : Steel / C-type Edge ength=12) PG PG mm SCM435 v c =200m/min Wet PG Hybrid and Good balance of sharpness and strength with double structure of flat and positive land design Step Wall Prevents chip entangling at high feed rate Twin Dots Improve chip control at low feed rate Control crater wear Hybrid land (Balance of sharpness and strength) Flat part (Braking area) Step Wall (Prevents chip entangling at high feed rate) Case Studies Wear Resistance Comparison SCM435 (Alloy steel) SCM435 Vc=300m/min ap=2.0 mm f=0.3mm/rev Wet Joint Vc=280m/min ap=3.0mm f=5mm/rev PG Time (min) 14 min 20 min 26 min PG () 400 more than pcs/edge Competitor l Stop cutting due to facture Competitor k 350 pcs/edge Competitor m Stop cutting due to facture achieves times longer tool life than Competitor k (CVD). PG Chipbreaker stabilized the chip condition and prevented burr formation. Good surface finish. 6

8 Negative type For Prevents chip entanglement and reduces cutting force at high feed cutting PQ Chipbreaker Features Stable chip control in a wide range of feed rates from finishing to medium realized by newly developed "Flat Zone" (Braking Area) and 2-steps rising smooth wall Twin dots on the cutting edge provide smooth chip control at low ap and high feed turning and facing Special designed Continuous Variable and (CV) with a well-balanced edge sharpness and toughness PQ PQ 150mm SCM435 Vc=200m/min Wet Twin Dots Flat Zone (Braking Area) Special Designed Continuous Variable and (CV) Specially designed positive land with the well-balanced combination of sharpness and toughness 2-step Smart Wall (2-step rising smooth surface) 2-steps light rising smooth wall design prevents damage dots at high feed cutting and provides excellent chip control in a wide range applications Chipbraking efficiency for a wide range of applications Flat Zone (Braking Area) 2-steps light rising wall design for small chip evacuation. Flat zone (Braking Area) achieving smooth chipbreaking (C12 type : Steel / C-type Edge ength=12) PQ Case Studies (Chip Control Comparison) Cutting Force Automotive part (S45C) Competitor n PQ Chipbreaker PQ Chipbreaker Conventional chipbreaker for semi-finishing 1800 Automotive part (S45C) PQ Chipbreaker prevents chip entanglement and minimizes breakage Competitor o PQ Chipbreaker Cutting force F [N] With Competitor o, chips were entangled in the turret and the process was interrupted frequently, but PQ Chipbreaker break chips into small pieces and improve productivity Feed rate f [mm/rev] Vc=200m/min, ap=2.0mm, type PQ Chipbreaker provides low cutting force in high feed cuttings. 7

9 Negative type For Solution for chip entanglement in small ap or high feed machining Features 3-dots design of PP smart chipbreaker is suitable for a wide range of feed rate in steel finishing Smooth Taper Cutting Edge reduces cutting force Corner-R mm-mm are available PP 1.5 PP 100mm SCM435 Vc=200m/min Wet 1.0 Smooth Taper Cutting Edge Reduced cutting force step Smart Dot Structure 3-dots design of PP smart chipbreaker The 3 different dots provide smooth chip evacuation in a wide range of feed rate (C12 type : Steel / C-type Edge ength=12) Each dot functions according to cutting conditions. 4 1st Dot Small ap and low feed rate 2nd Dot General use range 3rd Dot arge ap and high feed rate PP Case Studies (Chip Control Comparison) Automotive part (SCM420) Competitor p Cutting Force 800 Conventional chipbreaker for finishing prevents chip entanglement and provides stable machining Cutting force F [N] Automotive part (SCr420H) Competitor q prevents chip entanglement and provides stable machining Feed rate f [mm/rev] Vc=200m/min, ap=1mm, type provides low cutting force in high feed cuttings. 8

10 Stock Items (Negative) With Wiper Edge WP WP PS PS PS PS With Wiper Edge WQ WQ WQ PP PP PP PP PS PS PT PT PT PT PT GP GP GP PQ PQ PQ GT GT HQ HQ HQ HQ HQ PH PH PH CQ CQ CQ PH PH PH Up Facing Up Facing CQ CQ CJ CJ CJ CJ GS GS CNMM CNMM PH PH PH PH PX PX PX PX PX PX GS GS GS Single Sided CNMM PX PX PX PX PG PG PG PG ow Carbon Steel XP XP : Std. Item 9

11 Medium Cutting XQ XQ XS PP PP PP PP Up Facing CJ CJ CJ CJ GS GS GS GS GS PP PP PP PP GP GP GP GP GP PQ PQ PQ PQ PQ PQ HQ HQ HQ HQ HQ GS GS PG PG PG PG PG PG PG PG PS PS PS PS PS PS PS PT PT PT PT GT GT HQ HQ HQ CQ CQ CQ GT GT Up Facing CQ CQ CQ : Std. Item 10

12 Stock Items (Negative) Single Sided DNMM DNMM PH PH PH PH PH PH PX PX PX PX PX PX SNMG SNMG SNMG PH PH PH SNMG SNMG SNMM PH PH PH PH PX PX PX Medium Cutting XP XP XQ XQ Single Sided SNMM SNMM PX PX PX PX PX SNMG XP XS RNMG SNMG XQ RNMG Medium Cutting RNMG SNMG SNMG SNMG SNMG PQ PQ PQ HQ HQ HQ PG PG PG PS PS PS SNMG XS PP PP PP PP GP GP GP PQ PQ PQ HQ HQ SNMG PT PT HQ HQ HQ : Std. Item 11

13 Right-hand shown Up Facing CQ CQ CQ CQ CQ GS GS Medium Cutting XP XP XQ XQ GS GS XS PG PG PG ST ST PS PS PS PS PS PS PS PT PT GT GT VNMG VNMG VNMG VNMG PP PP PP PP GP GP GP VF VF VF PQ PQ PQ PH PH VNMG HQ HQ HQ VNMG Single Sided TNMM TNMM PH PH PH PX PX PX PX PX With Wiper Edge With Wiper Edge WP WP WQ WQ WQ : Std. Item 12

14 Stock Items (Negative) PP PP PP PP PQ PQ PQ PH PH 06T304HQ 06T308HQ Up Facing HQ HQ HQ HQ HQ CQ CQ CQ Medium Cutting XP XP XQ XQ XS Up Facing CJ CJ : Std. Item GS GS GS GS GS PG PG PG PG PS PS PS PS PT PT GT GT 13

15 Stock Items (Positive) Relief Angle Relief Angle CCMT PP PP CCMT 09T302PP 09T304PP 09T308PP CCMT GK GK CCMT 09T302GK 09T304GK CCMT GK GK GK CCMT HQ HQ DCMT DCMT DCMT DCMT GK GK GK 11T302GK 11T304GK 11T308GK HQ HQ HQ 11T302HQ 11T304HQ 11T308HQ DCMT XP CCMT 09T302HQ 09T304HQ 09T308HQ DCMT 11T302XP 11T304XP 11T308XP Medium CCMT 09T CPMT PP PP CPMT PP PP PP DCMT 11T304XQ 11T308XQ RCMX 1003M RCMX 1204M CPMT GP Medium CPMT GP GP CPMH HQ HQ SCMT 09T304HQ 09T308HQ CPMH HQ HQ SPMR Medium CPMH CPMH Medium SPMR CPMT XP CPMT XP XP TBMT DP DP Medium Cutting CPMT XQ XQ DCMT PP PP TCMT HQ HQ DCMT 11T302PP 11T304PP 11T308PP PP PP DCMT DCMT GP GP T304GP 11T308GP PP PP PP : Std. Item 14

16 Stock Items (Positive) Relief Angle eft-hand shown Relief Angle GP GP GP VBMT GP GP HQ HQ HQ HQ HQ HQ HQ XP VBMT VBMT VBMT VBMT GP GP VF VF VF VF VF VF VF HQ HQ XP XP VBMT HQ HQ HQ XP XP XQ XQ VCMT VF VF XQ XQ VCMT HQ HQ TPMR GP WBMT DP DP TPMR HQ HQ WBMT DP DP TPMR HQ HQ WPMT GP WPMT GP TPMR WPMT HQ HQ Medium TPMR WPMT HQ HQ : Std. Item : -hand Only CP317-3EN CAT/17T1312TYU