Sandvik Hyperion Metal Cutting. Gear Cutting Applications

Transcription

1 Sandvik Hyperion Metal Cutting Gear Cutting Applications

2 Hob Blanks Standard Hob blanks available with 12 teeth or 15 teeth configuration. Sandvik Hyperion Benefits: Reduction in EDM wire cutting - reduces edge stresses and provides a stronger cutting edge. Pre-formed Hob blanks reduce wire cutting costs by more than 50%. Pre-formed Hob blanks can reduce inventory needs and provide quicker lead times Sandvik Hyperion Grade offering - Longer tool life, Higher Productivity, and less grinding for re-sharpening. Sandvik Hyperion Consistent quality and performance - Every Time. O.D mm H1 H6F AM N S N S Hob Blank Grades available for roughing and finishing operations in steels ranging from HRC30 to HRC65. Sandvik Hyperion has developed Cemented Carbide Hob Blanks for demanding Gear Cutting and Hobbing operations. Sandvik Hyperion Hob Blanks provide longer cutting life, better edge security and higher productivity. Special Hob designs available upon request. 2

3 ISO Material Classification ISO CMC NO. MATERIAL P Steel SPECIFIC CUTTING FORCE KC 0.4 N/MM² HARDNESS BRINELL HB 01.1 UNALLOYED STEEL C= % C= % C= % LOW-ALLOY STEEL Non-hardened (alloying elements 5%) Ball bearing steel Hardened and tempered Hardened and tempered HIGH-ALLOY STEEL Annealed (alloying elements>5%) Hardened tool steel STEEL CASTING Unalloyed Low-alloy (alloying elements 5%) High-alloy (alloying elements>5%) Wear Behavior of Carbide Tooling ISO P HB All type of steels unalloyed, alloyed and cast steel with exception of steel with austenitic structure. Machinability Characteristic In general chip control is relatively easy and exhibit good machinability. BUE, material smearing tendency and heat zone increases with medium and high alloys (>10%). Grade Mapping Sheet P ISO ANSI Wear Process All materials in this group have typical crater and flank wear. Generally thermal, chemical and mechanical wear processes are equally balanced. Cutting edge needs to withstand plastic deformation for low alloyed and higher alloys steels. *The machinability of materials varies, depending on alloying elements, heat treatment and manufacturing process. HB Unalloyed, Low Alloy <5%, Alloyed Steel >5%, Sintered Steel Steel 01 C8 10 C C6 40 C5 PN90 DM80 AM50 H10F AM70 Toughness Wear Resistance 50 3

4 ISO Material Classification ISO CMC NO. MATERIAL M Stainless steel Wear Behavior of Carbide Tooling ISO M HB Stainless steel austenitic, austenitic-ferrite steel and cast steel (Duplex). Machinability Characteristic Machinability decreases with increase in alloying elements and exhibits high cutting forces and BUE. Work hardening of material can result in strong adhesion and BUE. Wear Process Grade Mapping Sheet Austenitic / ferritic / martensitic Stainless Steel, Cast Steel, Super Austenitic (Ni, 20%), Duplex Steel M ISO Stainless Steel ANSI DM80 Cutting edges are exposed to a great deal of heat, notch wear and BUE are common. Plastic deformation, followed by crater and abrasive wear. *The machinability of materials varies, depending on alloying elements, heat treatment and manufacturing process. AM50 SPECIFIC CUTTING FORCE KC 0.4 N/MM² MP40 HARDNESS BRINELL HB STAINLESS STEEL Non-hardened Bars/forged PH-hardened Ferritic/martensitic Hardened STAINLESS STEEL Austenitic Bars/forged PH-hardened Austenitic Super austenitic STAINLESS STEEL Non-weldable 0.05%C Bars/forged Weldable <0.05%C Austenitic-ferritic (Duplex) Stainless steel - Cast Non-hardened Ferritic/martensitic PH-hardened Hardened Stainless steel - Cast Austenitic Austenitic PH-hardened Super austenitic Stainless steel - Cast Non-weldable 0.05%C Austenitic-ferritic Weldable <0.05%C (Duplex) HB AM70 Toughness Wear Resistance 4

5 ISO Material Classification ISO CMC NO. MATERIAL K Cast iron Wear Behavior of Carbide Tooling ISO K HB Grey Cast Iron (GCI), cast Iron with spheroidal graphite, Malleable cast Iron (MCI), Nodular Cast Iron (NCI), Compacted Graphite Iron (CGI) and Austempered Ductile Iron (ADI). Machinability Characteristic Cast iron is, contrary to steel, a short-chipping type of material and low cutting forces. GCI and MCI are quite easy to machine, while NCI, CGI and ADI are more difficult. Wear Process Grade Mapping Sheet K Maleablle, K ISO Nodular, Grey, Compacted Grey Cast iron, Austempered Ductile Iron ANSI SPECIFIC CUTTING FORCE KC 0.4 N/MM² HARDNESS BRINELL HB 07.1 MALLEABLE Ferritic (short chipping) CAST IRON Pearlitic (long chipping) GREY CAST IRON Low tensile strength High tensile strength NODULAR SG IRON Ferritic Pearlitic Martensitic Thermal and mechanical loads from segmented chips induce crater and abrasive wear. BUE can be problem with nodular types which can lead to tool edge problem. *The machinability of materials varies, depending on alloying elements, heat treatment and manufacturing process. HB Cast Iron H10F AM70 Toughness Wear Resistance 5

6 ISO Material Classification Hardened material ISO CMC NO. MATERIAL H SPECIFIC CUTTING FORCE KC 0.4 N/MM² HARDNESS BRINELL HB 04.1 HARD STEEL Hardened and tempered HRC Extra hard steel Hardened and tempered HRC 10,1 CHILLED CAST IRON Cast or cast and aged HB Wear Behavior of Carbide Tooling ISO H HRC Hardened steel and cast iron materials, chilled cast iron. Machinability Characteristic The hardness makes them difficult to machine with high cutting forces. The materials generate heat during cutting and are very abrasive for the cutting edge. Wear Process High thermal and mechanical loads form fracture and deformation occurs. *The machinability of materials varies, depending on alloying elements, heat treatment and manufacturing process. Grade Mapping Sheet H ISO H Hardened Materials Hardened Materials, Stellites, Ferro-Tic ANSI 10 C4 20 C3 30 C2 40 C1 PN90 DM80 Toughness W. Resistance 6

7 Sandvik Hyperion Metal Cutting Solutions 7

8 SH-4005 ENG