BZN COMPACTS TOOL BLANKS AND INSERTS

Transcription

1 BZN COMPACTS TOOL BLANKS AND INSERTS

2 BZN COMPACTS TOOL BLANKS AND INSERTS Sandvik Hyperion manufactures a complete line of high quality polycrystalline CBN products for machining ferrous materials. The BZN product line is designed to provide significantly increased tool life, consistent surface finish and dimensional control. As a direct result overall part cost can be significantly decreased, while at the same time, gains in productivity as well as cost savings in the total manufacturing operation are successfully achieved. BZN tool blanks and inserts are available in a wide range of shapes, sizes and grades for fabrication into finished high performance tools. SIX SIGMA CONTROLLED QUALITY ENGINEERED FOR SUPERIOR PERFORMANCE A proprietary Six Sigma controlled manufacturing process provides the most consistent high quality blanks and inserts on today s market. BZN Compacts consist of fine particles of the highest quality Borazon CBN, sintered and integrally bonded to a cemented tungsten carbide substrate or produced as solid PCBN products. The CBN crystals are randomly orientated and strongly bonded either to each other or to a ceramic matrix. This provides the tool with high wear resistance combined with superior thermal and chemical stability. The carbide substrate provides excellent mechanical support to the PCBN abrasive layer and allows for easy braze attachment in the fabrication of finished tools. Higher material removal rates Decrease of cycle times Higher production output Faster/higher machining parameters Improved work piece quality Excellent dimensional control Consistent surface finishes Longer tool life Increased machine up-time Greater production capacity without investing in new equipment BZN COMPACTS THE CUTTING EDGE OF MODERN MACHINING BZN Compacts tool performance excels on pearlitic cast irons, Cr and Ni alloyed iron, hardened steel, powder metal irons, hard facing alloys and superalloys. In a typical machining application, tool cost is a relatively small percentage of the total production cost. The full potential and value of BZN compact tools over competitive and conventional tooling is evident by gains in productivity and cost savings in the total manufacturing operation. PRODUCT SELECTION CHART Pearlitic gray cast iron BZN 6000 BZN 7200S BZN 9100 Ductile iron BZN 9000 Hard cast iron (>45 HRc) BZN 9100 Hardened steel alloys (>45 HRc) BZN 7300S HPT 130 HPT 135 V20 V25 Sintered powder metal iron BZN 9000 BZN 9100 PM161 V20 V25 Superalloys BZN 6000 White iron BZN 7300S

3 BENEFITS OF BZN COMPACTS CARBIDE SUPPORTED Grade Characteristic CBN content (%) Applications BZN 6000 High abrasion resistance Excellent edge quality and retention Superior impact strength Produces fine surface finishes ~90% Interrupted cutting Pearlitic gray cast iron Tool and die steels Hard facing alloys Finishing of Ni and Co based superalloys BZN 9100 Excellent impact resistance Good chemical stability High wear resistance ~85% Continuous to interrupted cutting Cast iron Powder metal alloys Tool steel milling PM161 Improved microstructural homogeneity Superior impact resistance Improved wear and toughness compared to BZN 9100 Consistent and repeatable performance Excellent cutting edge quality and retention Chemical stability High wear resistance Provides excellent surface finish ~85% Continuous to interrupted cutting Cast iron Powder metal alloys Cylinder liner boring Gear turning Milling of tool steel ~65% Powder metal applications where alloy content is higher Exhaust and intake valve machining Continuous cutting HPT130 Superior chemical wear resistance Excellent surface finish Optimal thermal conductivity ~40% High speed continuous turning (finishing) Case hardened 220 m/min or greater Depth of cut 0.02 mm to 0.10 mm HPT135 V20 Excellent chemical and abrasion wear resistance Excellent surface finish Exceptionally long tool life Improved impact resistance Balance of flank wear and crater wear resistance Good chipping resistance ~55% Continuous to slightly interrupted cutting Case hardened steels Through hardened steels 180 m/min or greater Depth of cut 0.05 mm to 0.20 mm 60% to 65% Continuous to mild interrupted cutting Hardened Steel High Alloy Powdered Metal V25 Superior edge toughness Good flank and crater wear resistance at higher speeds 60% to 65% Continuous to medium interrupted cutting Hardened Steel High Alloy Powdered Metal SOLID PCBN Grade Characteristic CBN content (%) Applications BZN 7200S Course grain High fracture toughness Excellent wear resistance and chemical stability Tight dimensional control Consistent surface finish Increased productivity ~87% Ni-hard cast iron Hard cast iron, cylinder liners High chrome alloy steels Powder metal alloys Pearlitic gray cast iron Brake rotors/disks Finishing and roughing cuts BZN 7300S High abrasive wear resistance, Heat and chemical wear resistance Excellent impact toughness Performance achieved at higher speeds ~75% High chrome and Ni iron alloys (white iron) Turning of steel rolls Impellers and slurry pump machining Finishing and roughing cuts

4 PROPERTIES, THICKNESS, AVAILABILITY FULL ROUNDS CARBIDE SUPPORTED PCBN grade Nominal PCBN thickness Overall thickness (± 0.05 mm) PCBN layer thickness a a a a a a a a a a a a a a a a a a a a PM161 1 a a a HPT130 1 a a HPT135 1 a a a V20 1 a a V25 1 a a Available in 1-5 days All blanks are 59.1 mm diameter with 58.0 mm usable diameter. Made to stock Additional thicknesses may be available upon request. LASER AND EDM CUT INSERTS Shape Product code ANSI ISO IC IC Thickness Grade reference EDM cut PM161 Rounds BRNU-32X RNU-32 RNUN-0903 BRNU-33X RNU-33 RNUN BRNU-42X RNU-42 RNUN BRNU-43X RNU-43 RNUN BRNU-63X RNU-63 RNUN BRNU-83X RNU-83 RNUN Squares Rhombus Triangles BSNU-32X BSNU-33X BSNU-42X BSNU-43X BCNU-32X BCNU-33X BCNU-42X BCNU-43X BTNU-22X BTNU-32X BTNU-33X SNU-32 SNU-33 SNU-42 SNU-43 CNU-32 CNU-33 CNU-42 CNU-43 TNU-22 TNU-32 TNU-33 SNUN-0903 SNUN-0904 SNUN-1203 SNUN-1204 CNUN-0903 CNUN-0904 CNUN-1203 CNUN-1204 TNUN-1103 TNUN-1603 TNUN Unmarked items available upon request ships within 6 business days or less Made to stock * Coming in Q Not available in that thickness 7200 is laser cut as it is not conductible. Therefore the IC is oversized due to laser chipping and kerf. Additional IC's available upon request. THICK BZN 9100 COMPACTS FOR ENDMILLS Thick BZN 9100 cut parts offer a tungsten carbide base with a thicker CBN layer. The BZN 9100 Compacts parts are manufactured and sold as carbide supported cylinders that are to be manufactured into endmills for machining hardened ferrous materials. Performance characteristics machines harder materials provides a better finish single tool solution high-speed machining consistent and repeatable greatly improved life THICK BZN 9100 PRODUCT OFFERING PCBN layer Overall thickness PCBN layer tolerance Overall thickness tolerance Diameter / / (or 3.7)* +0.3 / / (or 6.5) +0.3 / / (or 4.5) +0.3 / / / / (or 7.5) +0.3 / / (or 6.3) +0.3 / / / / (or 10 or 8) +0.3 / / *Dimensions noted in parenthesis are available upon request.

5 SERVICE SHOP SANDVIK HYPERION UTILIZES THE LATEST IN EDM TECHNOLOGY Our service shop is capable of performing precision cutting services Complete your cut order in six business days or less from the day the order is received Each piece is cleaned and visually inspected to ensure you receive the highest level of quality and to minimize your internal processing time Precision cutting of BZN blanks includes standard shapes, customer special shapes, through holes, tight tolerance, relief angles, and carbide chamfers Service shop is outfitted with new technology, including wire EDM machines SANDVIK HYPERION NOMENCLATURE EXAMPLES Round 58.0 mm Length/ Angle Leg length or diameter OT Grade Special* Description R58.0/ Half round P/ mm Partial HPT PCBN 90P8.0/1.6-HPT PCBN Rectangle 8.0 mm mm 8.0 mm L8.0/ Triangle mm HPT135 60T5.0/-HPT135 Customer special 12.2 mm mm DXXXXXX/ R 2.0 Standard cut product tolerance for PCBN * Special = if not standard layer Leg length = ± 0.10 mm Thickness = ± 0.05 mm All dimension in millimeters Angle = ± 1 Chip Spec, EDM = 0.10 mm Diameter = ± 0.10 mm Chip Spec, Laser = 0.30 mm

6 SANDVIK HYPERION SH-4012 ENG BORAZON and BZN are registered trademarks of the Sandvik Group in Sweden and other countries.