MFK MFK. Double-sided insert with free cutting geometry to resist chatter. Multi-edge cutter for cast iron

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1 Multi-edge cutter for cast iron Double-sided insert with free cutting geometry to resist chatter 1 usable cutting edges per insert. ough edge with low cutting forces. New CVD grade C42M for longer tool life. NEW Ceramic insert with chipbreaker Wiper insert for finishing

2 Cutter for cast iron ough edge with low cutting forces enable stable machining. Uses 1-edge inserts for economical machining. 1 Low cutting forces prevent chattering Low cutting forces with helical cutting edge design. Cutting force comparison (In-house evaluation) 3, Resultant force in radial direction 1, Resultant force in axial direction Cutting force (N) 2,5 2, 1,5 1, 7 % Cutting force (N) % 5 2.R. Max. +15 Competitor Cutting conditions: Vc = 18 m/min, fz =.3 mm/t, ap ae = mm, dry Workpiece: GGG6, ø125 Competitor B 2 ough and reliable insert construction prevents fracturing ough and reliable dual angle edge design. Fracture resistance comparison (In-house evaluation) C42M Second main cutting edge First main cutting edge Surface finish comparison (In-house evaluation) Competitor C (CVD) Competitor D (CVD) Cutting time (min) Cutting conditions: Vc = 3 m/min, fz =.5 mm/t, ap = mm, wet Workpiece: Nodular cast iron (4 bores) 25 % Burr comparison Sharp cutting prevents burr formation Chattering creates poor surface Competitor F Burr Cutting conditions: Vc = 18 m/min, fz =.3 mm/t, ap ae = 3 78 mm, dry Workpiece:GGG6 Competitor E 1 Cutting direction

3 3 oolholder lineup to meet various applications Fine and extra fine pitch types available. Fine pitch (Example: ø125, 12 inserts) Recommended for unstable setups General purpose for wide application ranges Extra fine pitch (Example: ø125, 18 inserts) Recommended for rigid setups Finer pitch for higher efficiency 4 Chipbreaker lineup for wide range of applications General purpose: GM chipbreaker Heavy duty: GH chipbreaker Finishing: GL chipbreaker (Ground) Wiper edge: W chipbreaker (Ground) 5 Long tool life and stable machining C42M features advanced CVD coated CRIOS technology. Longer tool life Controlled α-l2o3 crystal growth for improving wear resistance and fracture resistance. Prevents film peeling 4 % improved film adhesion by optimized interface. Increased edge strength Higher film strength and fracture resistance with high aspect ratio icn. CRIOS technology icn layer CRIOS technology Conventional CRIOS technology Carbide substrate Conventional CRIOS technology is Kyocera s original CVD coating technology. Insert grade lineup Long tool life (1st recommendation) C42M Stable machining Use ceramic insert for high speed machining (see page 3). Fracture resistance PR1525 Wear resistance comparison (In-house evaluation) Wear (mm) C42M Competitor G Fracture Cutting time (min) Cutting conditions: Vc = 2 m/min, fz =.3 mm/t, ap ae = 8 mm, dry Workpiece: Nodular cast iron 2

4 Ceramic grades for high speed and high efficiency machining Low cutting force ceramic insert with chipbreaker controls edge chipping. Cutting force comparison (In-house evaluation) 1,5 Resultant force in radial direction 8 Resultant force in axial direction Cutting force (N) 1, 5 26 % DOWN Cutting force (N) % Rake angle +6.7 Competitor H Cutting conditions: Vc = 6 m/min, fz =.1.25 mm/t, ae ap = mm, dry Workpiece: GG25, ø125, 1 insert Competitor I First recommendation for gray cast iron 1 High wear resistance enables stable machining Reduces grain boundary phase that generates negative impact on the cutting performance. Conventional grade Less grain boundary phase Stable machining without chipping More grain boundary phase Unstable machining due to chipping Mechanical and thermal property will be improved by controlling grain boundary phase. he grain boundary phase contained a high proportion of glass, therefore its toughness will be weakened by cutting heat. Grain boundary phase Grain boundary phase Point2 Sudden fracture prevention Crack propagation Fracture resistance improvement L has higher aspect ratio compared with conventional grade. Bridging Crack deflection Crack d spect ratio = L/d Large aspect ratio Controls crack propagation CS75 First recommendation for nodular cast iron Wear resistance improvement due to high coating adhesion Suitable for high speed cutting High wear resistant phase (ic base) Special l2o3 phase High adhesion phase (in base) Si3N4 substrate 3

5 face mill E a ød2 ød b S H 7 E a ød2 ød ød2 ød ød1 ød1 ød1 #1 #2 b ød ød1 S 7 H Rake angle ( ) Description.R. R.R. 8R- -7 1R- -6 (M.) 125R R- ød2 ød b ød3 ød b ød2 ød3 ød5 H H E a G E a G ød4 ød1 øc ød ød1 S 7 #3 #4 øc øc1 ød1 ød4 ød6 ød ød1 S 7 oolholder dimensions Bore dia. Fine pitch Extra fine pitch Description vailability No. of inserts 8R-11-8-M Dimensions (mm) ød ød1 ød2 ød ød1 ød2 H E a b s ød3 ød4 ød5 ød6 øc øc1 G Drawing Weight (kg) # R-11-1-M # R M # R M # R-11-2-M # R M # R M MO # R-11-1-M # R M # R M # R M # R M # R M # R M MO # : vailable MO: Made to order Spare parts and applicable inserts Description Wedge Wedge screw Spare parts Wrench Mounting bolt pplicable inserts Description Wedge Wedge screw Spare parts Wrench Mounting bolt pplicable inserts 8R-11-1-M 1R M HH1235 HH164 PNMG116NEN-GM PNMG116NEN-GH 8R-11-8-M 1R-11-1-M HH1235 HH R M PNEG116NEN-GL 125R M PNEG116NER-W 16R M C9N W618N R M C9N W618N -15 PNE116NN- 2R M 12 2R-11-2-M 25R M 315R M PNEG116NR R M 315R M PNMG116NEN-GM PNMG116NEN-GH PNEG116NEN-GL PNEG116NER-W PNE116NN- 12 PNEG116NR

6 pplicable inserts Description Insert Surface finish oriented PNMG116NEN-GM PNMG116NEN-GH PNEG116NEN-GL PNEG116NER-W PNE116NN PNEG116NR ough edge MEGCO NNO General CVD Si3N4 coated ceramic Si3N4 ceramic C42M PR1525 CS75 CVD Coated carbide Dimensions (mm) Wiper insert (2-edge) High speed NEW High speed (With chipbreaker) : vailable 5

7 Recommended conditions 1st recommendation 2nd recommendation Workpiece material Insert grade Cutting speed (m/min) Chipbreaker Feed per tooth fz (mm/t) C42M GM.25 Gray cast iron GH PR1525 GL.12 C42M GM.2 Nodular cast iron GH PR1525 GL.1 Recommended application range Workpiece: Gray cast iron Workpiece: Nodular cast iron ap (mm) W GL GM GH ap (mm) 6, 4, 2, GL W GM GH ,1,2,3,4 fz (mm/t) fz (mm/t) Notes: 1. When using W (wiper), please use together with GM or GH. (Not recommended for use with GL) 2. When using wiper, do not exceed fz =.2 or insert corner may be damaged. he main cutting edge of W (wiper) insert is receding from that of GM and GH. herefore, the feed rate for the insert next to W (wiper) is double that of other inserts. Recommended conditions (Ceramic) 1st recommendation 2nd recommendation Without chipbreaker Workpiece material Insert grade Cutting speed (m/min) Edge preparation Feed per tooth fz (mm/t) Gray cast iron Nodular cast iron With chipbreaker CS75 CS Workpiece material Insert grade Cutting speed (m/min) Edge preparation Feed per tooth fz (mm/t) Gray cast iron Nodular cast iron CS75 CS Recommended application range (Ceramic) Workpiece: Gray cast iron, nodular cast iron Without chipbreaker With chipbreaker fz (mm/t) 6

8 Case studies Machine base GG25 Base GG , 8 8 Vc = 16 m/min fz =.16 mm/t (Vf = 782 mm/min) ap ae = 3 1 mm Dry 125R (12 Inserts) PNMG116NEN-GM / Vc = 16 m/min fz =.18 mm/t (Vf = 917 mm/min) ap ae = 3 14 mm Dry 2R-11-2 (2 Inserts) PNMG116NEN-GM / C42M Chip removal rate Competitor J (12 Inserts) 125 cc/min 235 cc/min Efficiency 2 imes Chip removal rate C42M Competitor K (12 Inserts) 167 cc/min 385 cc/min Efficiency 2.3 imes Little noise and vibration with increased cutting speed and feed rate. (User evaluation) C42M performed at 2.3 times the efficiency of Competitor K. Little noise and stable machining. (User evaluation) Mold part GGG6 Bed GG3 2.2 m 1 m Vc = 9 m/min fz =.34 mm/t (Vf = 974 mm/min) ap ae = 2 6 mm Dry 8R-11-8 (8 Inserts) PNMG116NEN-GM / PR1525 Vc = 15 m/min fz =.26 mm/t (Vf = 1,242 mm/min) ap ae = 3 1 mm Dry 16R (16 Inserts) PNMG116NEN-GM / C42M Machining efficiency PR1525 Competitor L (8 Inserts) 1 pcs/edge 3 pcs/edge ool Life 3 imes Chip removal rate C42M Competitor M (8 Inserts) 372 cc/min 93 cc/min Efficiency 4 imes Competitor L had chipping after machining 1pc. PR1525 kept good edge condition and stable machining after machining 3 pcs. (User evaluation) C42M improved the efficiency by 4 times compared with Conventional M. (User evaluation) 215 KYOCER Corporation E8

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