SANDVIK HYPERION BZN COMPACTS TOOL BLANKS AND INSERTS

Transcription

1 SANDVIK HYPERION 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 Iron BZN 6000 BZN 9100 BZN 9500 Ductile Iron BZN 9000 Hard Cast Iron BZN 9500 BZN 9100 Hardened Steel HPT130 HPT135 V20 Sintered Powder Metal Iron BZN 9500 BZN 9100 BZN 9000 PM93 Super Alloys BZN 6000 White Iron BZN 7300S BZN 7000S BZN 7400S V25 V35 BZN 7300S PM161 V25 V35 2 SANDVIK HYPERION

3 SANDVIK HYPERION BENEFITS OF BZN COMPACTS CARBIDE SUPPORTED GRADE CHARACTERISTIC CBN CONTENT (%) APPLICATIONS BZN High Abrasion Resistance - Wear Resistance - Excellent edge quality and retention - Superior Impact Strength - Produces Fine surface finishes ~90% - Severe Interrupted Cuts - Pearlitic Gray Cast Iron - Tool and Die Steels - Hard Facing Alloys - Sintered Alloys - Finishing of Ni and Co based Superalloys - Turning of Sintered Carbide (>16% Cobalt Content) BZN Excellent Impact Resistance - Good Chemical Stability ~85% - Continuous to Interrupted cuts - Cast Iron - Powder Metal Alloys - Tool Steel Milling BZN Improved Microstructural homogeneity - Superior Impact Resistance - Improved Wear and Toughness compared to BZN Consistent and repeatable performance - Excellent cutting edge quality and retention ~85% - Continuous to Interrupted cuts - Cast Iron - Powder Metal Alloys - Cylinder liner boring - Gear Turning - Milling of Hardened Steel - Turning of Sintered Carbide (>16% Cobalt Content) BZN PM93 - Complementary Grade to BZN Enhanced wear properties compared to 9500 ~83% - Powder Metal applications where carbide content is lower - Continuous to medium Interrupted cuts BZN Excellent abrasion resistance - Good Chemical Stability ~83% - Excellent in machining of ductile iron - Powder Metal applications where carbide content is lower - Continuous to lightly interrupted cuts BZN PM161 - Excellent Chemical Stability - Impact Resistant - Provides Excellent Surface Finish ~65% - Sintered metals with high alloy content - Exhaust and Intake valve Machining - Continuous Cuts BZN HPT130 - Superior Chemical Wear Resistance - Excellent Surface finish ~40% - High Speed Continous Turning (finishing) - Case Hardened 220m/min or greater BZN HPT135 - Excellent Chemical and Abrasion Wear Resistance - Excellent Surface Finish - Exceptionally long tool life - Improved Impact Resistance to HPT130 ~55% - Continous to slightly interrupted cuts - Case Hardened Steels - Thru hardened Steels - Typical 180m/min or greater BZN V20 - Excellent balance of flank and crater wear resistance - Good chipping resistance - Suitable for both wet and dry conditions ~60% - Continous to mild interrupted turning - Hardened Steel & cold work tool steels - Typical m/min BZN COMPACTS 3

4 SANDVIK HYPERION BENEFITS OF BZN COMPACTS CARBIDE SUPPORTED GRADE CHARACTERISTIC CBN CONTENT (%) APPLICATIONS BZN V25 - Superior Edge toughness - Good flank and crater wear resistance - Suitable for both roughing and finishing cuts. ~65% - Continous to medium interruption - Hardened steels - Powder metal machining - CV joint applications (milling and turning) - Typical m/min BZN V35 - Superior Edge toughness - Suitable for both roughing and finishing cuts. ~70% - Mild to heavy interruption - Valve seat machining - CV joint applications - Typical m/min SOLID PCBN GRADE CHARACTERISTIC CBN CONTENT (%) APPLICATIONS BZN 7000S BZN 7200S - High fracture toughness - Excellent wear resistance & chemical stability - Tight dimensional control - Consistant surface finish - High fracture toughness compared BZN 7000S - Excellent wear resistance & chemical stability - Tight dimensional control - Consistant surface finish - Increased Productivity ~85% ~87% - Ni-hard Cast Iron - Hard Cast Iron, Cylinder Liners - High Chrome Alloy Steels - Powder Metal Alloys - Pearlitic Gray Cast Iron - Brake Rotors/Disks - Depths of cut up to 4mm - Ni-hard Cast Iron - Hard Cast Iron, Cylinder Liners - High Chrome Alloy Steels - Powder Metal Alloys - Pearlitic Gray Cast Iron - Brake Rotors/Disks - Depths of cut up to 4mm BZN 7400S - Tailored particle distribution for higher cutting speeds - High fracture toughness - Excellent wear resistance & chemical stability - Tight dimensional control - Consistent surface finish - Superior Thermal conductivity ~88% - Ni-hard Cast Iron - Hard Cast Iron, Cylinder Liners - High Chrome Alloy Steels - Powder Metal Alloys - Pearlitic Gray Cast Iron - Brake Rotors/Disks - Depths of cut up to 4mm BZN 7100S - High abrasive wear resistance, - Heat and chemical wear resistance - Excellent Impact Toughness - Performance achieved at higher speeds - Optimized particle distribution for optimal performance - 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 & Slurry Pump Machining - Depths of cut up to 5mm BZN 7300S ~75% - High Chrome and Ni Iron Alloys (White Iron) - Turning of Steel Rolls - Impellers & Slurry Pump Machining - Depths of cut up to 5mm 4 SANDVIK HYPERION

5 SANDVIK HYPERION PROPERTIES, THICKNESS, AVAILABILITY GRADE NOMINAL PCBN THICKNESS (mm) FULL ROUNDS CARBIDE SUPPORTED OVERALL THICKNESS (± 0.05 mm) PCBN LAYER THICKNESS (mm) a a a a a a a a a a a a a a a a a a a PM93 1 a a a a a a a PM161 1 a a a HPT130 1 a a a HPT135 1 a a a a V20 1 a a a V25 1 a a a a V35 1 a a a = Ships within 3 business days All blanks are ~59.1 mm Diameter with 58.0 usable diameter. = Made to Stock Note: Additional thicknesses may be available upon request. SHAPE Rounds Squares Rhombus Triangles PRODUCT CODE REFERENCE BRNU-32X BRNU-33X BRNU-42X BRNU-43X BRNU-63X BRNU-83X BSNU-32X BSNU-33X BSNU-42X BSNU-43X BCNU-32X BCNU-33X BCNU-42X BCNU-43X BTNU-22X BTNU-32X BTNU-33X ANSI RNU-32 RNU-33 RNU-42 RNU-43 RNU-63 RNU-83 SNU-32 SNU-33 SNU-42 SNU-43 CNU-32 CNU-33 CNU-42 CNU-43 TNU-22 TNU-32 TNU-33 EDM AND LASER CUT SEMI-FINISHED INSERTS ISO IC (mm) IC (mm) GRADE THICKNESS Laser Cut EDM Cut EDM Cut Laser Cut (mm) RNUN RNUN RNUN RNUN RNUN RNUN SNUN-0903 SNUN-0904 SNUN-1203 SNUN-1204 CNUN-0903 CNUN-0904 CNUN-1203 CNUN-1204 TNUN-1103 TNUN-1603 TNUN /7200/7400 grades are laser cut as the material is not conductable. Therefore the IC is oversized due to laser chipping and kerf. Additional sizes and shapes may be available upon request. HPT130, HPT135, V-series, and VS-series can be ordered as full top inserts upon request. Maximum thickness is 3.2 mm. Made to stock Blank = Made to order, ships in 5 business days or less BZN COMPACTS 5

6 SANDVIK HYPERION 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 PCBN LAYER (mm) OVERALL THICKNESS (mm) THICK BZN 9100 PRODUCT OFFERING PCBN LAYER TOLERANCE (mm) OVERALL THICKNESS TOLERANCE (mm) DIAMETER (mm) / / (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. 6 SANDVIK HYPERION

7 BZN V-Series BZN V-Series Machining of hardened steels continues to be ever more challenging as alloying compositions change and machine tools & fabrication features evolve. The variety of applications at any end user requires a stocking of multiple PCBN grades. Thus there is an inherent need for PCBN grades that can adequately cover these wide ranging applications. With this motivation, Sandvik Hyperion introduces the new BZN V-Series, i.e. Versatility-Series, to allow customers maximum flexibility in machining of hardened ferrous materials. The BZN V-Series grades are designed to provide versatility in 3 key aspects: Workpiece composition Case hardened, Bearing steels, Powder metal alloys, Alloy steels and Tool Steels. Application demands Turning, milling, reaming. Component type Bearings, shafts, gears, CV joint components, valve seat machining and die/mold components. In addition to versatility in applications, BZN V-Series provides customers with enhanced wear and fracture resistance, performance repeatability and uniform layer thickness. 360 HPT130 Cutting speed, m/min V20 HPT135 V25 V35 BZN H05 H15 H25 H35 Interruption level BZN COMPACTS 7

8 V20 PCBN Grade for Hardened Steel Machining 0.3 SANDVIK Grade V20 Flank wear, mm 0.15 HTM Comp CBN V20 Designed for continous to mild interrupted turning. Excellent balance of flank and crater wear resistance. Good chipping resistance. Suitable for both wet and dry conditions Cutting time, mins. Work Material- 100Cr6, HRc Insert CNGA Vc= 130 m/min, ap= 0.25mm, f= 0.1mm/rev, Dry Applications Grade V20 is recommended for machining: Hardened steel (wet, dry). Valve seat materials. Cold work tool steels. Competitor CBN Grades V Number of components Work Material- 100Cr6, HRc 58 Taper bearing Vc= 200 m/min, ap= 0.17mm, f= mm/rev,wet Grade Summary Grade cbn Content (%) Binder cbn particle size (μm) Hardness (GPa) Cutting Speed (m/min) Feed Rate (mm/rev) Depth of cut (mm) Coolant Edge Preparation (General) V TiCN Dry, Wet S mm x 25º light hone 8 SANDVIK HYPERION

9 V25 PCBN Grade for Hardened Steel Machining Flank wear, mm BZN8200 Coated Competitor CBN V25 SANDVIK Grade V25 Designed for continous to medium interrupted applications. Good flank and crater wear resistance at higher cutting speeds. Superior edge toughness. Suitable for both roughing and finishing cuts Cutting time, min. Work Material- 21NiCrMoS2, HRc Insert CNGA Vc= 200 m/min, ap= 0.15mm, f= 0.2mm/rev, dry Applications Grade V25 is recommended for: Medium interrupted turning. Powder metal machining. CV Joint applications. Grades V25 Competitor CBN Distance, km Work Material- 100Cr6, HRc Interrupted turning Vc= 160m/min, ap= 0.2mm, f= 0.15mm/rev Grade Summary Grade cbn Content (%) Binder cbn particle size (μm) Hardness (GPa) Cutting Speed (m/min) Feed Rate (mm/rev) Depth of cut (mm) Coolant Edge Preparation (General) V TiN Dry S mm x 25º light hone BZN COMPACTS 9

10 V35 PCBN Grade for Hardened Steel Machining Grades Competitor V35 SANDVIK Grade V35 Designed for mild to heavy interrupted applications. Superior edge toughness. Suitable for both roughing and finishing cuts Distance machined, km Work Material- 100Cr6, HRc Interrupted turning Vc= 160m/min, ap= 0.2mm, f= 0.15mm/rev Applications Grade V35 is recommended for: Heavy Interrupted turning. Valve seat machining. CV Joint applications. Grades Competitor CBN V # of valve seats Powder Metal Valve Seat Machining Vc= 100m/min, f= 0.1mm/rev Plunge cut Grade Summary Grade cbn Content (%) Binder cbn particle size (μm) Hardness (GPa) Cutting Speed (m/min) Feed Rate (mm/rev) Depth of cut (mm) Coolant Edge Preparation (General) V TiN Dry S SANDVIK HYPERION

11 BZN VS-Series H05 H15 H25 H35 H50 VS Series VS10 VS20 VS25 VS35 Wear HPT130 HPT135 V20 V25 V35 Toughness BZN VS-Series To further strengthen the V-series launched last year, Hyperion launches the VS series at IMTS The grade chain offers significantly improved toughness while maintaining the superior crater and abrasion resistance properties. Key attributes Improved toughness and chipping resistance. Solid PCBN (no carbide support). Flexibility in tool design and geometry. Eliminates coefficient of thermal expansion mismatch between tungsten carbide and PCBN during tool fabrication. cbn content (%) Target Application VS10 50 Continuous to light interruption VS20 60 Continuous to light interruption VS25 65 Light to medium interruption VS35 75 Light to heavy interrupted BZN COMPACTS 11

12 SANDVIK HYPERION 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 five 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 PCD 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 SH-4012 ENG LT Copyright 2016 Sandvik Group All rights reserved SANDVIK HYPERION NOMENCLATURE EXAMPLES Length/Angle Leg length or diameter OT Grade Special* Description Round R58.0/ mm Half round P10.0/ mm Partial HPT PCBN 90P8.0/1.6-HPT PCBN 8.0 mm Rectangle L8.0/ mm 8.0 mm 5.0 mm 60 Triangle HPT135 60T5.0/3.2-HPT135 Customer Special 12.2 mm 10.0 mm R 2.0 DXXXXXX/ Standard cut product tolerance for PCD * Special = if not standard layer Leg Length = +/ mm Diameter = +/ mm EDM Chip Spec = 0.10 mm IC (inscribed circle ) = +/ mm Angle = +/- 1 Degree Thickness = +/ mm Laser Chip Spec = 0.20 mm All dimensions in mm SANDVIK HYPERION