Stainless Steel Machining

Transcription

1 Stainless Steel Machining 1

2 Table of contents UGITECH in few words. Stainless steel machinability : Definition & Criteria Role of Inclusions. (Sulphides, Oxides, UGIMA Oxides) Machinability Comparisons Grades Data Ugitech : expertise, experience, customization 2

3 UGITECH 2008 Key figures: Turnover 750 Million Euros Sales 195 Kt Employees 2000 p. 3

4 UGITECH Our ambition: optimize our positions on the world markets : 2 main markets Strong presence in Europe and a ambition to develop Export 2008 figures 2008 figures 4

5 UGITECH A wide range of products to answer the customer demand: Round Bars Hexagonal Wire rod Drawn wire Bars 5

6 UGITECH. Three key factors of success which make the difference: CUSTOMIZATION : Thanks to commercial and technical assistance for the customers needs; INNOVATION : Through a policy of our offer s evolution (product / service) and strong skills in marketing and R&D; RELIABILITY : With a single streams management and an unique control system ( SAP). 6

7 Machinability : Definition & Criteria A tentative definition The ability to undergo a shaping process by removing the excess material in a form of chips with a cutting tool. crater wear trailing edge notch wear depth of cut notch wear flank wear The ability of the SS to generate short well broken chips Good Bad 7

8 Machinability : Definition & Criteria How to measure The ability of stainless steels to avoid too important tool wear Tool Vb 15/0.15 Test f = 0.25 mm/rev a p = 1.5 mm f ap Vc Usure Vb (1/100 mm) Ugima 4307HM - coulée n rond de 73 Outil : KC kennametal Temps (min) 300m/min 320m/min Looking for the cutting speed Vc to have a flank wear of 0.15 mm in 15 min of effective cutting. Higher is the V b15/0.15 better is the grade Flank wear PCV Expo - Stainless Steel Machining 8

9 Machinability : Definition & Criteria How to measure The ability of stainless steels to generate small well broken chips Tool The Chip Breaking Zone UGI 4462 Insert: Sumitomo AC610M CNMG NGU 0,4 f ap Vc 0,35 0,3 short chips Looking for the area (in terms of feed rate and depth of cut) where the chips are short enough 0,25 f (mm/tr) 0,2 0,15 long chips Wider the blue zone is better is the grade 0,1 0,5 1 1,5 2 2,5 3 3,5 4 ap (mm) 9

10 Machinability : Role of inclusions Classification of stainless steels Stainless steels can be classified in 3 families depending on their machinability Easy to machine : , , (High Sulphur) Fairly to machine : , (Low Sulphur) Hard to machine : , , ESRR grades... (Very low sulphur) 10

11 Machinability : Role of inclusions Role of sulphides Basically manganese sulphides Malleable at the temperature reached in the cutting area : 0.025% S Localisation of the deformation in shear zones around them Easier chip breaking Easier chip removal : 0.300% S 11

12 Machinability : Role of inclusions Role of sulphides Basically manganese sulphides Malleable at the temperature reached in the cutting area Formation of a lubrication layer Allows higher speeds Increase tool life But Manganese sulphides lower the other properties of Stainless Steels (corrosion resistance, forgeability, weldability,...) 12

13 Machinability : Role of inclusions Role of the oxides Uncontrolled oxides Natural oxides are very hard / brittle They hurt machining tools Alumina Chromites Silica 13

14 Machinability : Role of inclusions Role of the oxides SiO 2 Controlled oxides : UGIMA Formation of specific oxides 2 liq 1700 Cris No bad effect on tool life Trid Ugima Oxides Hot rolling c3s c3s c2s Pswl Gehl Anor 1500 Mull 1800 Cor Chaux c3a ca6 CaO Al 2 O 3 ca c12a ca

15 Machinability : Role of inclusions Role of the UGIMA oxides Basically Al 2 O 3 -SiO 2 -CaO Oxides Malleable at the temperature reached in the cutting area (if high cutting speeds) : 0.025% S Localisation of the deformation in shear zones around them Easier chip breaking Easier chip removal : 0.025% S + UGIMA oxides 15

16 Machinability : Role of inclusions Role of the UGIMA oxides Basically manganese sulphides Malleable at the temperature reached in the cutting area Formation of a lubrication layer Allows higher speeds Increase tool life And UGIMA Oxides do not lower the other properties of Stainless Steels (corrosion resistance, forgeability, weldability,...) 16

17 Grades : Machinability comparisons UGIMA effects Feed : 0.25 mm/rev Depth of cut : 1.5 mm No lubricant Tool : Z250 Stellram SNMG Turning Speed (m/min) With carbide tools UGIMA = increase of cutting speed / productivity of 25% UGIMA Corrosion Resistance S <

18 Grades : Machinability comparisons UGIMA effects 500 UGIMA 4305 Feed : 0.25 mm/rev Depth of cut : 1.5 mm No lubricant Tool : Z250 Stellram SNMG Turning Speed (m/min) With a carbide tool UGIMA = + 45% Productivity UGIMA UGIMA = + 25% Productivity S = 0.300% 200 S < 0.030% Corrosion Resistance 18

19 Grades : UGIMA 4542 Improved machinability precipitation hardening martensitic steel Productivity increased +30% compared with standard grade Tool life : Doubled Greater ease in carrying out delicate machining operations. 19

20 Grades : UGIMA 4057 Improved machinability martensitic steel Increase in Productivity : +10% -> 20% compared with standard grade Tool life : Doubled Greater ease in carrying out delicate machining operations. Coated Carbide Insert Turning Drilling with plain carbide 6 mm diameter drill Drilling with HSS 4 mm diameter drill Chip flow (cm3/mn UGINE % UGIMA 4057 Q (cm3/mn) Chips flowx (cm3/mn) UGINE % UGIMA 4057 Chips flow (cm3/mn) 2 1,5 1 0,5 0 UGINE % UGIMA

21 30 UGIMA grades available DESIGNATION CONFORM TO EUROPE / USA EN AISI 1 - UGIMA 4301 = UGIMA X5 Cr Ni UGIMA 4301FG = UGIMA 304FG X5 Cr Ni UGIMA 4307 = UGIMA 304L X2 Cr Ni L 4 - UGIMA 4307FG = UGIMA 304L FG X2 Cr Ni L 5 - UGIMA 4307HM = UGIMA 304L HM X2 Cr Ni L 6 - UGIMA X2 Cr Ni L 7 - UGIMA 4306FG X2 Cr Ni L 8 - UGIMA 4567 = UGIMA 304CU X3 Cr Ni Cu 9 - UGIMA 4305 = UGIMA NSU X8 Cr Ni S UGIMA 4305HD = UGIMA 303HD X8 Cr Ni S UGIMA 4305HM = UGIMA NSU HM X8 Cr Ni S UGIMA 303XL UGIMA 4570 = UGIMA 303UX X6 Cr Ni Cu S UGIMA 4401 = UGIMA X5 Cr Ni Mo UGIMA 4401FG = UGIMA 316FG X5 Cr Ni Mo UGIMA 4404 = UGIMA 316L X2 Cr Ni Mo L 17 - UGIMA 4404FG = UGIMA 316L FG X2 Cr Ni Mo L 18 - UGIMA 4404HM = UGIMA 316L XL X2 Cr Ni Mo L 19 - UGIMA 4436 = UGIMA 316Mo X3 Cr Ni Mo UGIMA 4435 = UGIMA 316LMo X2 Cr Ni Mo UGIMA 4435FG = UGIMA 316LMoFG X2 Cr Ni Mo UGIMA 4435ICH = UGIMA 316LWI X2 Cr Ni Mo UGIMA 4571 = UGIMA 316Ti X6CrNiMoTi Ti 24 - UGIMA 4460 = UGIMA X3 Cr Ni Mo N UGIMA 4021 = UGIMA 420A X20 Cr A 26 - UGIMA 4006 = UGIMA X12 Cr UGIMA 4028 = UGIMA 420B X30 Cr B 28 - UGIMA 4542 = UGIMA X5 CrNiCuNb UGIMA 4057 = UGIMA X17CrNi UGIMA X14CrMoS17 21

22 UGITECH : Tailor-made technical expertise A very innovative Research Center at our customer service: TO INNOVATE : Means To launch new products, To develop current products, To optimize the industrial process, To adopt recent technologies from R&D center. 20 % of our today products did not exist 6 years ago. Providing of finished pieces, Customized products. 22

23 UGITECH : Quality & reliability Quality and reliability remain our priorities. Values shared by all the Ugitech s employees. Customers recognize UGITECH as the reference in technical products. Experts dedicated to the operational needs of customers Experts dedicated to our metallurgical process. Constant quality to reach «0 defect» internally as well as externally The respect for delivery times is a major objective of commercial and production teams 23

24 Thank You for your Attention PCV Expo - Stainless Steel Machining 24