CA65 15/25 & PR11 25 CA65. Solution for Stainless Steel Machining. Minimizes Notching. Prevents Burrs. Reduces Buil-up Edge.

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1 CA65 15/25 & PR PR11 & 15/25 CA65 Solution for Machining Minimizes Notching. Prevents Burrs. Reduces Builup Edge. For FinishingMedium Chipbreaker! MQ TZE00048

2 New Coated CA65 15 / PR11 25 CA6515/CA6525 (CVD coating) and PR1125 (PVD coating) is applicable to various types of machining such as stainless steel, heatresistant steel and steel, etc. CA65 15/25 Thin Ultra Fine TiCN CVD coated carbide grade Improves wear resistance Smoothness TiN Surface Smoothness / Welding Resistance Toughness αal2o3 High Temperature Stability / Crater Wear Resistance Special Interlayer High Binding Force / Prevents Peeling Ultra Fine TiCN Improved Fracture Resistance and Wear Resistance due to the High Aspect Ratio and Fine Columnar Structure PR11 25 Fine surface thin TiAlN Stable machining with tough substrate Low cutting force on fine surface TiAlNbased coating Fine surface TiAlN coating Micro grain carbide substrate High fracture toughness Smooth Coating Film Surface Reduces adhesion and edge buildup Low cutting force on smooth surface <CA65 15/25 Coating> <PR11 25 Coating> Application Range Cutting Speed High speed Low speed CA65 15 (First recommended Grade) PR11 25 Bright Gold Coating FS Fine Surface Coat Continuous Light interruption Heavy interruption Application Conventional CVD Coating Conventional PVD Coating Cutting capability Cutting Performance of CA6525 Stabilization CA6525 CVD A company's CVD coating Vc:V=100m/min D=0.5mm f=0.3mm/rev Wet Four grooves The frequency of damage Cutting Performance of PR1125 Stabilization PR1125 PVD A company's CVD M25 coating A company's CVD M35 coating Vc:V=100m/min D=1.5mm f=0.3mm/rev Wet Four grooves The frequency of damage Wear resistance Vc:V=200m/min D=1.5mm f=0.3mm/rev Wet Wear resistance and burr condition Vc V=120m/min D=1.0mm f=0.15mm/rev Wet Hour of cutting 30min 0 Small burr Less wear Vb max wear / mm A company's CVD coating PR1125MU A company's CVD M25 coating No adhesion Large burr Heavy wear Adhesion CA6525 CVD Chip feeds into the machine Cutting time / min A company's CVD M35 coating Large notching Heavy wear 1

3 The edge preparation is the key to machine stainless steel! New edge preparation Introduce the 'FET Technology (Fine edge treatment)' which realizes large edge strength and sharp rake angle. Small R horning Prevents burrs OK! Cutting edge condition by FET Technology No Good A Comp. A Feature of New Chipbreaker for Stainless Machining Chip control oriented type Chipbreaker First recommended chipbreaker from medium to roughing Positive land Tough cutting edge Good chip control D.O.C. (mm) Feed Rate(mm/rev) 0.3 New! MQ Chipbreaker From finishing to Medium 5 4 Large rake angle,circular edge line D.O.C. (mm) 3 2 Low cutting force and Good chip control MQ Feed Rate(mm/rev) Sharpness oriented type MU Chipbreaker from Medium to Roughing Large rake angle, Low cutting force Reduces notching & burrs D.O.C. (mm) MU Feed Rate(mm/rev) 0.3 Combination of CA65 15/25, PR11 25 and chipbreaker for stainless steel is preferable to prevent welding and burr as well as chattering for low carbon steel or heat resistance alloy machining. 2

4 Stock Items I.C. Thickness Hole CornerR I.C. Thickness Hole CornerR HQ HQ HQ PS PS PS FinishingMedium MediumRoughing PS PS PS PS PS PS PT PT MediumRoughing PS PS PS PT PT MediumRoughing PT PT PT MediumRoughing/ High Feed PT PT GU GU Roughing GU GU Finishing GU GU Finishing HU HU HU HU MediumRoughing NEW FinishingMedium MQ MQ MediumRoughing NEW HU HU MQ MQ MediumRoughing MediumRoughing MediumRoughing MU MU MU TK TK 1.6 FinishingMedium MediumRoughin MQ MQ MU MU 3 FinishingMedium HQ HQ HQ HQ MediumRoughin MU MU :Std Stock

5 Stock Items I.C. Thickness Hole CornerR Righthand shown I.C. Thickness Hole CornerR MediumRoughin TK TK TK TK MediumRoughing/High Feed PT PT SNMG HQ FinishingMedium Roughing SNMG PS PS PS GU GU MediumRoughing Finishing SNMG PT PT HU HU MediumRoughing/High Feed MediumRoughing NEW SNMG MQ MQ Roughing FinishingMedium NEW FinishingMedium SNMG MQ MQ MediumRoughing MediumRoughing SNMG MediumRoughing MU MU HQ HQ TK TK FinishingMedium MediumRoughing PS PS PS $ST $ST MediumRoughing PS PS TNGG $S $S Finishing/Surface MediumRoughing Roughness Oriented :Std Stock 4

6 Stock Items Righthand shown I.C. Thickness Hole CornerR CA 6515 CA 6525 PR 1125 I.C. Thickness Hole CornerR MediumRoughing Low cutting resistance TNGG $25R $25R Finishing GU GU VNMG MediumRoughing HU HU Roughing VNMG GU GU NEW FinishingMedium MQ MQ NEW Finishing VNMG MQ MQ MediumRoughing FinishingMedium VNMG MediumRoughing MU MU MediumRoughing TK TK VNMG MU MU MediumRoughing MediumRoughing CCMT HQ HQ MediumRoughing HQ HQ CCMT 09T302HQ 09T304HQ 09T308HQ MediumRoughing PS PS PS FinishingMedium CCMT GK GK MediumRoughing/High Feed PT PT CCMT 09T302GK 09T304GK CCMT GK GK GK Roughing FinishingMedium :Std Stock

7 Stock Items I.C. Thickness Hole CornerR I.C. Thickness Hole CornerR CCMT 09T VBMT HQ HQ Medium CPMH HQ HQ VBMT HQ HQ FinishingMedium CPMH HQ HQ VCMT HQ FinishingMedium FinishingMedium CPMH WPMT HQ Medium CPMH WPMT HQ HQ DCMT DCMT GK GK GK 11T302GK 11T304GK 11T308GK FinishingMedium SPMR FinishingMedium DCMT HQ HQ Medium SPMR DCMT 11T302HQ 11T304HQ 11T308HQ TPMR HQ HQ FinishingMedium TPMT HQ TPMR HQ HQ FinishingMedium TPMT HQ HQ TPMR TPMT HQ HQ TPMR FinishingMedium Medium :Std Stock 6

8 Case Studies (Austenitic ) (Austenitic ) Connector Nipple Vc=120m/min ap=2mm f=mm/rev pcs/edge ø34 16 Vc=120m/min ap=2.5mm f=0.15mm/rev pcs/edge 18 ø20 Competitor A 200pcs/edge Competitor B 15pcs/edge Compared to competitor coated A, chipbreaker shows good chip evacuation and wear resistance, and improved the tool life by almost 300%. Kyocera's coating is two times longer than Competitor B. Chip evacuation. Pump cover (Austenitic ) Vc= m/min ap= mm f= mm/rev (Austenitic ) Pump parts Vc=150m/min ap=1.5m f=mm/rev MQ (CA6515) CA pcs/edge 100pcs/edge Competitor C 5pcs/edge Competitor D 50pcs/edge Compared to competitor C, Kyocera's coating improves chip evacuation and leads to longer tool life. chipbreaker doubled the tool life of Competitor D (Austenitic ) (Austenitic ) Jig Pin Vc=100 m/min ap=1.0 mm f=0 mm/rev pcs/edge Vc=140m/min ap=2.0mm f=0.3mm/rev ø pcs/edge ø15 Competitor E 80pcs/edge Competitor F 350pcs/edge Kyocera's coating is 1.8 times longer than Competitor E. Compared to competitor F, CA6525 demonstrated a better edge condition with longer tool life. chipbreaker provided better chip control. 7

9 Case Studies (Austenitic ) (Austenitic ) Connector Shaft Vc= m/min 46 Vc=100m/min ap= mm f= mm/rev 42 ap= mm f=0.15mm/rev (PR1125) PR pcs/edge (PR1125) PR pcs/edge Competitor G 120pcs/edge Competitor H 0.5pcs/edge Kyocera's coating is 1.3 times longer than Competitor G. Kyocera's cutting length is 2 times longer than Competitor H. (Competitor H was not able to cut even 1 workpiece) Edge condition is excellent compared to Competitor H. Housing Vc=122m/min (Martensitic ) Sleeve (Precipitation hardening ) Vc=100m/min ap=1 2mm f=0.18mm/rev ø16 ap=mm f=0.15mm/rev ø30 ø MU More than 4,000pcs/edge 350pcs/edge Competitor I 2,000pcs/edge Competitor J 200pcs/edge chipbreaker doubled the tool life of Competitor I. Compared to competitorj, CA6525 provided better chip control with longer tool life. Housing Vc=80m/min Permalloy (FeNi) (Stainless steel cast steel) Valve seat Vc=120m/min ap=0.7mm f=0.12mm/rev ø180 ø50 ap=1.0mm f=0.10mm/rev MU 34pcs/edge pcs/edge Competitor K 12pcs/edge Competitor L 30pcs/edge By changing the edge face machining and the chipbreaker, cutting evacuation was improved and the machine did not stop operating. This also helped to extend tool life. The coating life is two times longer than Competitor L. The chip evacuation is the same as others. 8

10 Heat resistance alloy machining Inconel 718 (HighTemp.Alloy) Inconel 718 (HighTemp.Alloy) Shaft ROUND BAR Vc=50m/min CA6525 Shaft ROUND BAR Vc=50m/min PR1125 ap=2mm ap=2mm f=0.1mm/rev f=0.1mm/rev Wet Comp.M M35CVD Wet Comp.N M25PVD PS CA pcs/edge PR pcs/edge Competitor M 1 1 / 2 pcs/edge Competitor N 3 pcs/edge machined more than 2 times as many workpieces as Competitor M. Cutting edge condition of was better than Competitor M. PR11 25 showed superior wear resistance and machining stability compared with Competitor N. 9

11 Recommended Grade for Machining Austenitic (1.4301,1.4845,1.4401) Machinability (Hardest to cut) Significant work hardening, poor cutting performance, acceleration of wear at cutting edge (notching) Heat conductivity is extremely poor (onequarter of carbon steel), temperature at edge rises and likely to wear Welding or builtup edge occurs easily, cutting resistance increases and edge breakage or chipping is likely Chips tend to become longer and stronger, resulting in poor machinability <Recommended grade> Classification Grade Cutting speed (m/min) M15 M25 M <Recommended Chipbreaker> Application ap(mm) Continuous Light Interruption Interruption Heavy Interruption more than 1mm /MU /MU more than 1mm /MU /MU more than 1mm /MU /MU Ferritic (1.4002,1.4006,1.4016) Machinability <Recommended grade> Limited work hardening and more machinable than austenitic steel (less notching and burring) Lower hardness due to ferritic structure (will not harden when quenched) Heat conductivity is poor (half of carbon steel), temperature at edge rises and likely to wear Classification Grade Cutting speed (m/min) M15 M25 M /MU /MU <Recommended Chipbreaker> Application ap(mm) Continuous Light Interruption Interruption Heavy Interruption more than 1mm /MU /MU more than 1mm /MU /MU more than 1mm /MU /MU Martensitic (1.4000,1.4006,1.4021) Machinability <Recommended grade> Limited work hardening and more machinable than austenitic steel (less notching and burring) High in hardness, likely to cause crater wear Heat conductivity is poor (half of carbon steel), temperature at edge rises and likely to wear Classification Grade Cutting speed (m/min) M15 M (70160) 130 (80170) 150 (80220) 180 (120240) 190 (130250) 160 (90230) (130250) 160 (90230) /MU /MU <Recommended Chipbreaker> Application ap(mm) Continuous Light Interruption Interruption Heavy Interruption more than 1mm /MU /MU more than 1mm /MU /MU /MU Precipitation hardening (PH) stainless steel (1.4542,1.4568) Machinability (Hard to cut) <Recommended grade> High tensile strength (approx. twice that of other stainless steels), high cutting resistance and hard to machine/low machinability Heat conductivity is poor, temperature at edge rises and likely to wear Classification Grade Cutting speed (m/min) M15 M (50110) 70 (40100) <Recommended Chipbreaker> Application ap(mm) Continuous Light Interruption Interruption Heavy Interruption more than 1mm /MU /MU more than 1mm /MU /MU /MU 10

12 Recommended Cutting Speeds Insert Grade (m/min) Machining CA65 15 PR11 25 Continuous Continuous / Interruption Continuous / Interruption Austenitic Stainless 180 (120240) 150 (80220) 120 (70160) Ferritic Stainless 190 (130250) 160 (90230) 130 (80170) Martensitic Stainless 190 (130250) 160 (90230) Precipitation hardening Stainless 80 (50110) 70 (40100) Case of troubles Troubleshooting Notching (breakage) Select grades with high flexural strength such as CA6525, PR1125 to lessen notching (breakage) Select MU () chipbreaker (with large rake angle, improved cutting performance and less work hardening) Chipbreaker MU Chipbreaker Burrs Make depth of cut deeper than workhardened layer from preprocess Vary depth of cut to disperse concentration of workhardened layer at notched section Increase the feed rate (higher than 0.1mm/rev), and lessen work hardening Increase cutting edge angle to lessen concentration of load on the edge Adhesion/Builtup edge Choose bright coating CA6515, CA6525 for surface smoothness Select /MU chipbreaker with large rake angle Increase the cutting speed, increase the coolant concentration Crater wear Select SUS grades CA6515 and CA6525 Select MU chipbreaker with large rake angle (to improve cutting performance and control rise in edge temperature) Decrease the cutting speed to control the rise in edge temperature Decrease the feed rate to reduce tool load chipbreaker:first recommended chipbreaker form medium to roughing Chip control Chipbreaker MQ chipbreaker:good chip control from finishing to medium MQ Chipbreaker