CARBIDE GRADE SELECTION/APPLICATION GUIDE

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1 / INSERTS / TECHNICHAL INFORMATION CARBIDE GRADE SELECTION/APPLICATION GUIDE Steels P Steels ISO P50 P40 P30 P20 P10 P01 Typical ailure modes Fracture Chipping Deormation Chipping Deormation Crater Deormation Wear Application Roughing General purpose Finishing * *5625 MTCVD coated carbide 8515 * Uncoated carbide S4 SY3 Cermet NTB10 Ceramics TC100** * ** 56 General Catalog

2 CARBIDE GRADE SELECTION/APPLICATION GUIDE / INSERTS / TECHNICHAL INFORMATION Steels (continued) Negative top orm geometry MTCVD coated Uncoated Cermet P Steels S4 SY3 NTB10 Depth o cut mm Free machining & low carbon steels Medium carbon & high carbon steels Alloy steels & easy to machine tool steels Tool steels & die steels GP F M5 M5 366 M5 M5 GP R3 366 R3 R3 R3 F M5 396 M5 M5 M8 R R3 R3 R3 R3 GP M5 M5 M5 M5 F F2 F2 F2 M5 M3 R R3 R3 R3 R3 GP M5 M5 M8 M5 F F2 F2 F2 M5 M3 R R3 R3 R3 60 M8 GP R3 R3 R3 M8 F R R3 R GP M8 M F 396 F5 F R R3 R GP M8 M F R M7 FT M7 FT GP M7 FT M7 FT F R M7 FT M7 FT GP M7 M F GP F F4 360 F4 300 F4 - - Customer Service - Tel.: +33 (0) Fax: +33 (0)

3 / INSERTS / TECHNICHAL INFORMATION CARBIDE GRADE SELECTION/APPLICATION GUIDE Steels (continued) Positive top orm geometry MTCVD coated Uncoated Cermet P Steels S4 NTB10 Depth o cut mm. Free machining & low carbon steels Medium carbon & high carbon steels Alloy steels & easy to machine tool steels Tool steels & die steels GP F PF4* PF4* 366 PF4* - - GP F PF4* 396 PF4* PF4* - - GP - - F PF4* PF4* PF4* - - GP - - F PF4* PF4* PF4* - - R PM2* PM2* PM2* - - GP PM2* PM2* PM2* - - F GP PM2 PM2 PM2 - - F 366 PM2 PM2 PM2 - - R PM2* PM2* PM2* - - GP PM2* PM2* PM2 - - F R PM5 PM GP PM5 PM F GP F PF4 360 PF4 300 PF General Catalog

4 CARBIDE GRADE SELECTION/APPLICATION GUIDE / INSERTS / TECHNICHAL INFORMATION Stainless steels M Stainless steels ISO M40 M30 M20 M10 Typical ailure modes Fracture Chipping Chipping Fracture Wear Chipping Application Roughing General purpose Finishing **8620 PVD coated carbide *9605 **KR MTCVD coated carbide * * Uncoated carbide N KX2 * c) ** c) Customer Service - Tel.: +33 (0) Fax: +33 (0)

5 / INSERTS / TECHNICHAL INFORMATION CARBIDE GRADE SELECTION/APPLICATION GUIDE Stainless steels (continued) Negative top orm geometry M Stainless steels PVD coated MTCVD coated Uncoated 8620 KR N KX2 Depth o cut mm Ferritic & martensitic Austenitic PH & duplex R M8 M5 M8 M5 M8 M5 GP M5 M2 M5 M2 M5 M2 F M M2 M2 R M8 M5 M8 M5 M8 M5 GP M5 M2 M5 M2 M5 M2 F M2 M2 M2 GP - - M7 M7 F - - M2 M2 R M8 M8 M8 GP M8 M8 M8 F M2 M3 M2 M3 M2 M3 R R3 R3 R3 GP M8 M5 M8 M5 M8 M5 F M2 M3 M2 M3 M2 M3 GP M5 M4 M5 M4 M5 M4 F M4 M2 M4 M2 M4 M2 R GP M5 M4 M5 M4 M5 M4 F M4 M2 M4 M2 M4 M2 R - - M7 M7 GP M5 M4 M5 M4 M5 M4 F - - F5 F5 R M7 M7 M7 GP M7 M7 M7 F M7 M7 M7 R M5 M7 M5 M7 M5 M7 GP M5 M2 M5 M2 M5 M2 F M5 M2 M5 M2 M5 M2 60 General Catalog

6 CARBIDE GRADE SELECTION/APPLICATION GUIDE / INSERTS / TECHNICHAL INFORMATION Stainless steels (continued) Positive top orm geometry M Stainless steels PVD coated MTCVD coated Depth o cut mm Ferritic & martensitic Austenitic PH & duplex GP PM2* PM2* PM2* F PM2* PM2* PM2* GP - - PM2* PM2* F - - GP PM2* PM2* PM2* F PF4* PF4* PF4* GP PM2* PM2* PM2* F PF4* PF4* PF4* R PM2* PM2* PM2* GP PM2* PM2* PM2* F PM2* PM2* PM2* GP PM2 PM2 PM2 F PM2 PM2 PM2 GP PM2 PM2 PM2 F PM2 PM2 PM2 GP PM5 PM5 PM5 F Customer Service - Tel.: +33 (0) Fax: +33 (0)

7 / INSERTS / TECHNICHAL INFORMATION CARBIDE GRADE SELECTION/APPLICATION GUIDE Cast iron K Cast irons ISO K30 K20 K10 K01 Typical ailure modes Fracture Chipping Wear Chipping Wear Application Roughing General purpose Finishing 5625 *5615 MTCVD coated carbide *1510 *1505 Uncoated carbide N Ceramics SN100 TC100 * c) 62 General Catalog

8 CARBIDE GRADE SELECTION/APPLICATION GUIDE / INSERTS / TECHNICHAL INFORMATION Cast iron (continued) Negative top orm geometry K Cast irons MTCVD coated Depth o cut mm Gray cast iron HB Gray cast iron HB Ductile & malleable cast iron HB Ductile & malleable cast iron HB Powder metals R R3 FT R3 FT R3 FT R3 FT R3 FT GP R3 R3 R3 R3 R3 F M7 M7 M7 M7 M7 R R3 FT R3 FT R3 FT R3 FT R3 FT GP R3 R3 R3 R3 R3 F M8 M8 M8 M8 M8 R - GP - F R - GP F Customer Service - Tel.: +33 (0) Fax: +33 (0)

9 / INSERTS / TECHNICHAL INFORMATION CARBIDE GRADE SELECTION/APPLICATION GUIDE Cast iron (continued) Positive top orm geometry K Cast irons MTCVD coated Uncoated N Depth o mm Gray cast iron HB Gray cast iron HB Ductile & malleable cast iron HB Ductile & malleable cast iron HB Powder metals - - GP PM5 PM5 PM5 PM5 PM5 F PF4* PF4* PF4* PF4* PF4* - - GP PM5 PM5 PM5 PM5 PM5 F PF4* PF4* PF4* PF4* PF4* - - GP PM2* PM2* PM2* PM2* - - F GP PM5 PM5 PM5 PM5 - - F PM5 PM5 PM5 PM General Catalog

10 CARBIDE GRADE SELECTION/APPLICATION GUIDE / INSERTS / TECHNICHAL INFORMATION Aluminum & non-errous N Aluminum - Non-errous ISO N40 N30 N20 N10 Typical ailure modes Wear Wear Wear Chipping Application Roughing General purpose Finishing 8620 PVD coated carbide *KR20 *KX20 Uncoated carbide N KX2 PCD *D720 / PC30 * Customer Service - Tel.: +33 (0) Fax: +33 (0)

11 / INSERTS / TECHNICHAL INFORMATION CARBIDE GRADE SELECTION/APPLICATION GUIDE Aluminum & non-errous (continued) Positive top orm geometry N Aluminum & Non-errous PVD coated Uncoated KX KR20 N KX2 Depth o mm Aluminum alloys < 7% silicon Aluminum alloys 7-12% silicon Aluminum alloys > 12% silicon Copper alloys GP 1L* 1L* 1L* 1L* F 1L* 1L* 1L* 1L* GP PM2* PM2* PM2* PM2* F GP F PM2* PM2* PM2* PM2* GP 1L* 1L* 1L* 1L* F 1L* 1L* 1L* 1L* GP 1L* 1L* 1L* 1L* F 1L* 1L* 1L* 1L* 66 General Catalog

12 CARBIDE GRADE SELECTION/APPLICATION GUIDE / INSERTS / TECHNICHAL INFORMATION High temp alloys S High temp alloys ISO S40 S30 S20 S10 Typical ailure modes Deormation Fracture Chipping Deormation Wear Deormation Application Roughing General purpose Finishing KX20 PVD coated carbide **8620 **KR20 ** MTCVD coated carbide * Uncoated carbide **N **KX2 Ceramics *WS500 * ** Customer Service - Tel.: +33 (0) Fax: +33 (0)

13 / INSERTS / TECHNICHAL INFORMATION CARBIDE GRADE SELECTION/APPLICATION GUIDE High temp alloys (continued) Negative top orm geometry S High temp alloys PVD coated MTCVD coated Uncoated 8620 KR KX N KX2 Depth o cut mm Iron base alloys A-286 discalloy, incoloy Nickel base alloys monel, hastelloy, inconel, waspaloy Cobalt base alloys haynes stellite Titanium alloys 6Al-4V GP M5 M2 30 M5 M2 - - M5 M2 F F5 30 F5 - - F5 GP M5 M2 M5 M2 M5 M2 M5 M2 F 99 F5 F5 F5 F5 GP F5 M2 60 F5 M2 FT F5 M2 F M2 M2 60 FT M2 GP M2 M2 M2 M2 F F5 F5 F5 F5 GP M5 M4 M5 M4 M5 M4 - - F M4 M2 M4 M2 M4 M2 - - GP M5 M4 M5 M4 M5 M4 - - F M4 M2 M4 M2 M4 M2 - - R M7 M5 M7 M5 M7 M5 - - GP M5 M4 M5 M4 M5 M4 - - F F5 F5 F5 - - R M7 GP M7 F GP M2 F General Catalog

14 CARBIDE GRADE SELECTION/APPLICATION GUIDE / INSERTS / TECHNICHAL INFORMATION High temp alloys (continued) Positive top orm geometry S High temp alloys PVD coated MTCVD coated Uncoated 8620 KR KX N KX2 Depth o cut mm Iron base alloys A-286 discalloy, incoloy Nickel base alloys monel, hastelloy, inconel, waspaloy Cobalt base alloys haynes stellite Titanium alloys 6Al-4V GP PM2* PM2* - - PM2* F PM2* 30 PM2* - - PM2* GP PM2* PM2* PM2* PM2* F GP PM2* 60 1L 2L PM2* 1L 2L F 1L 2L 1L 2L 60 1L 2L 1L 2L GP F 1L 1L 1L GP PM5 PM5 PM5 - - F PM2 PM2 PM2 - - GP PM5 PM5 PM5 - - F GP PM5 PM5 PM5 PM5 F GP PM5 F L 2L GP PM5 F L 2L Customer Service - Tel.: +33 (0) Fax: +33 (0)

15 / INSERTS / TECHNICHAL INFORMATION CARBIDE GRADE SELECTION/APPLICATION GUIDE Hardened materials H Hardened materials ISO H40 H30 H20 H10 Wear Wear Typical ailure modes Chipping Wear Fracture Deormation Application Roughing General purpose Finishing PVD coated carbide *9605 MTCVD coated carbide **1510 **1505 Coated ceramics TC100 CBN *C225 * ** 70 General Catalog

16 CARBIDE GRADE SELECTION/APPLICATION GUIDE / INSERTS / TECHNICHAL INFORMATION Hardened materials (continued) Negative top orm geometry MTCVD coated PVD coated H Hardened materials Depth o cut mm Alloy steels HRC Alloy steels HRC Tool & die steels HRC GP F FT FT FT GP FT FT FT F FT FT FT GP F FT FT FT Positive top orm geometry MTCVD coated PVD coated H Hardened materials Depth o cut mm Alloy steels HRC Alloy steels HRC Tool & die steels HRC GP F FT FT FT GP F FT FT FT GP F FT FT FT Customer Service - Tel.: +33 (0) Fax: +33 (0)

17 / INSERTS / TECHNICHAL INFORMATION ADVANCED MATERIAL GRADE SELECTION/APPLICATION GUIDE Cast iron Negative top orm geometry Ceramic silicon nitride K Cast iron SN100 Depth o cut mm Gray cast iron HB Ductile & malleable cast iron HB Gray cast iron HB Ductile & malleable cast iron HB Powder metals R GP F Aluminum & non-errous Negative top orm geometry N Aluminum & non-errous Depth o cut mm Aluminum alloys < 7% silicon Aluminum alloys 7-12% silicon Aluminum alloys > 12% silicon Copper alloys Polycrystalline Diamond PCD D720 / PC30 R GP F F F F F High temp alloys Negative top orm geometry S High temp alloys Depth o cut mm Iron base alloys A-286 discalloy, incoloy Nickel base alloys monel, hastelloy, inconel, waspaloy Cobalt base alloys haynes stellite Titanium alloys 6Al-4V Ceramic WS500 R GP F General Catalog

18 / INSERTS / TECHNICHAL INFORMATION ADVANCED MATERIAL GRADE SELECTION/APPLICATION GUIDE Hardened materials Negative top orm geometry CBN Ceramic H Hardened materials C225 TC100 Depth o cut mm Alloy steels HRC Alloy steels HRC Tool & die steels HRC R GP F R GP F Positive top orm geometry H Hardened materials Depth o cut mm Alloy steels HRC Alloy steels HRC Tool & die steels HRC CBN C225 R GP F Customer Service - Tel.: +33 (0) Fax: +33 (0)

19 / INSERTS / TECHNICHAL INFORMATION CARBIDE GRADE SELECTION/APPLICATION GUIDE Cast iron (continued) Positive top orm geometry K Cast irons MTCVD coated Uncoated N Depth o mm Gray cast iron HB Gray cast iron HB Ductile & malleable cast iron HB Ductile & malleable cast iron HB Powder metals - - GP PM5 PM5 PM5 PM5 PM5 F PF4* PF4* PF4* PF4* PF4* - - GP PM5 PM5 PM5 PM5 PM5 F PF4* PF4* PF4* PF4* PF4* - - GP PM2* PM2* PM2* PM2* - - F GP PM5 PM5 PM5 PM5 - - F PM5 PM5 PM5 PM General Catalog

20 / INSERTS / TECHNICHAL INFORMATION INSERT DIMENSIONS C orm 80 l ød m1 m r a s ød 1 Negative styles a = 0º CNGA CNMA CNGN CNGG CNMG CNGX CNMM Positive styles a = 7º a = 11º a = 11º CCGT CPGX CPGN CCMT CCMW CCMX Insert designation d l s r m m 1 d 1 CCGT L CCGT L C C C C CCGT L CCGT L C C C C C CCGT 09 T3 02-1L CCGT 09 T3 04-1L CCGT 09 T3 08-1L C T C T C T CC CC CC CN CN CN CN CN C C C C C C C C C C C C C General Catalog

21 / INSERTS / TECHNICHAL INFORMATION INSERT DIMENSIONS D orm 55 ød a Negative styles a = 0º DNGA DNMA DNGN DNMG DNGX DNMM DNMX Positive styles a = 7º a = 11º a = 11º DCGT DCGW DCMT DCMW l m r s ød 1 Insert designation d l s r m m 1 d 1 DCGT L DCGT L D D D DCGT 11 T3 02-1L DCGT 11 T3 04-1L DCGT 11 T3 08-1L D T D T D T D T D D D D D D D D D D D D D D D E orm 75 ød a Positive styles a = 7º a = 11º a = 11º ECGT EPGX ECMT EPMT ECMW l r s ød 1 m Insert designation d l s r m m 1 d 1 E ECGT L E E E ECGT L E E Customer Service - Tel.: +33 (0) Fax: +33 (0)

22 / INSERTS / TECHNICHAL INFORMATION INSERT DIMENSIONS K orm a Negative styles r a = 0º 55 l ød s KNUX Insert designation d l s r m m 1 d 1 KNUX KNUX R orm a Negative styles Positive styles ød 1 a = 0º RNMG RNGN a = 7º a = 11º a = 7º a = 11º RCMT RCGX RPGN RCMX RPGX ød s Insert designation d l s r m m 1 d 1 R R R R MO R R R R T3 MO R R MO R R R MO R R MO R R MO R MO General Catalog

23 / INSERTS / TECHNICHAL INFORMATION INSERT DIMENSIONS S orm a Negative styles Positive styles a = 0º SNGA SNMA SNGN SNMG SNGX SNMM SNUN a = 7º a = 11º a = 11º SCGT SCMT SCMW ød m r s ød1 Insert designation d l s r m m 1 d 1 S S S S SCGT 09 T3 04-1L SCGT 09 T3 08-1L S T S T S S S SC SC SN SN SN SN S S S S S S S S S S S S S S S S S S Customer Service - Tel.: +33 (0) Fax: +33 (0)

24 / INSERTS / TECHNICHAL INFORMATION INSERT DIMENSIONS T orm 60 m l r ød a s ød 1 Negative styles a = 0º TNGA TNMA TNGN TNMG TNUN TNMM Positive styles a = 7º a = 11º a = 11º a = 20º TCGT TPGN TEEW TCMT TPGX TCMX TPMR TPUN TPUX Insert designation d l s r m m 1 d 1 T T T T T T TCGT L TCGT L T T T T T T T T T TCGT 16 T3 04-1L TCGT 16 T3 08-1L T T T T T T T T T T T T T T T T T T T T T T T T T T T T T T General Catalog

25 / INSERTS / TECHNICHAL INFORMATION INSERT DIMENSIONS V orm 35 l ød m r a s ød 1 Negative styles a = 0º VNGA VNMG VNMM Positive styles a = 5º a = 7º a = 11º VBMT VCGT VPEX VCGW VCGX Insert designation d l s r m m 1 d 1 V V VCGT L VCGT L VPEX 11 T VPEX 11 T VPEX 11 T VCGX VCGX VCGT L VCGT L VCGT L V V V VCGT L VCGT L VCGT L V V V W orm m l 80 ød r a s ød 1 Negative styles a = 0º WNGA WNMA WNMG WNMM WNMX Positive styles a = 7º a = 11º a = 11º WCGT WCGX Insert designation d l s r m m 1 d 1 W W W W W W W W W W W Customer Service - Tel.: +33 (0) Fax: +33 (0)

26 / INSERTS / TECHNICHAL INFORMATION WIPER GUIDELINES 6W Used or semi-inish and inishing operations. Allows increased productivity while producing suraces as good as those produced by conventional inserts. How wiper inserts work Conventional inserts produce a certain inish (Ra) at a given eed rate. Using wiper inserts can improve inish or increase eed rate. WIPER WIPER Ra Ra/2 Ra Ra 2x Wiper inserts operating at the same eed rate as conventional inserts can improve surace inish by up to 50%. Wiper inserts can also produce suraces equal to those o conventional inserts while doubling the eed rate. Depth o cut mm Surace inish Ra W W Get improved chip control and improved tool lie at existing eed rates while improving surace inishes by 50%. Innovative wiper corner radius design improves surace inish compared to conventional inserts with the same corner radius. Wiper usage guidelines CNMG and WNMG wiper inserts produce a true corner radius equal to the radius produced by non-wiper inserts. DNMG wiper inserts produce corner radius that is not true ; but is within tolerance range o most manuacturing requirements. 80 General Catalog

/ INSERTS / TECHNICHAL INFORMATION INSERT FAILURE MODES Problem / Failure mode Cause Control action / Remedy

Use harder grade Select more positive rake chipbreaker Flood cutting zone with coolant Crater Excessive

oxide coating Select more positive rake chipbreaker Flood cutting zone with coolant Heat deormation

Select harder grade Built-up edge, torn inish, chip welding Low cutting speed Poor shearing action Increase

cutting zone with coolant Edge chipping Excessive eed rate Reduce eed rate Interrupted cut Select tougher

notching Scale part High work hardening materials Decrease κ r Increase cutting speed Select tougher grade

27 / INSERTS / TECHNICHAL INFORMATION INSERT FAILURE MODES Problem / Failure mode Cause Control action / Remedy Rapid lank wear Excessive cutting speed Reduce cutting speed Work material micro-structure contains carbides Use harder grade Select more positive rake chipbreaker Flood cutting zone with coolant Crater Excessive cutting speed Excessive eed Ineective use o coolant Reduce cutting speed & eed Select harder grade with oxide coating Select more positive rake chipbreaker Flood cutting zone with coolant Heat deormation Excessive heat Reduce cutting speed Excessive cutting orces Reduce eed rate Flood cutting zone with coolant Select harder grade Built-up edge, torn inish, chip welding Low cutting speed Poor shearing action Increase cutting speed Select more positive rake chipbreaker Select tougher grade (use PVD coated insert) Flood cutting zone with coolant Edge chipping Excessive eed rate Reduce eed rate Interrupted cut Select tougher grade Select stronger chipbreaker Improve rigidity Decrease κ r or increase hone Excessive depth o cut notching Scale part High work hardening materials Decrease κ r Increase cutting speed Select tougher grade Select stronger chipbreaker Vary depth o cut i possible (Ramping) Customer Service - Tel.: +33 (0) Fax: +33 (0)

/ INSERTS / TECHNICHAL INFORMATION INSERT FAILURE MODES Problem / Failure mode Cause Control action / Remedy Fracture Improper selection o grade/chipbeaker and/or cutting

cutting temperatures Interrupted cut Reduce eed rate Increase cutting speed Select stronger chipbreaker Turn o coolant Poor surace inish High eed rate Reduce eed rate and

smoother surace Workpiece chatter vibration Poor set-up Improper insert selection Select more positive rake chipbreaker Increase κ r Use smaller nose radius Unacceptable chip

28 / INSERTS / TECHNICHAL INFORMATION INSERT FAILURE MODES Problem / Failure mode Cause Control action / Remedy Fracture Improper selection o grade/chipbeaker and/or cutting conditions Reduce eed rate Select tougher grade Select stronger chipbreaker Make sure set-up is as rigid as possible Replace Shim Seat Thermal cracks Extreme variation in cutting temperatures Interrupted cut Reduce eed rate Increase cutting speed Select stronger chipbreaker Turn o coolant Poor surace inish High eed rate Reduce eed rate and increase cutting speed Low cutting speed Select more positive rake chipbreaker Nose radius too small Flood cutting zone with coolant Use larger nose radius Select a grade with smoother surace Workpiece chatter vibration Poor set-up Improper insert selection Select more positive rake chipbreaker Increase κ r Use smaller nose radius Unacceptable chip control (Low carbon steel) Low eed rate Large nose radius Increase κ r Use smaller nose radius Decrease lead angle Ensure use o correct chipbreaker run at recommended parameters 82 General Catalog

29 / INSERTS / TECHNICHAL INFORMATION FORMULAE Parameters to determine Known parameters Formula Machined diameter (mm) D m Cutting speed () Spindle speed (rev/min) n Spindle speed (rev/min) Cutting time (min) n T Cutting speed () Machined diameter (mm) Machined length (mm) per revolution () Spindle speed (rev/min) Proile depth (μm) R t per revolution () n Insert nose radius (mm) r ε Metal removal rate (cm 3 /min) Power requirement (kw) Torque requirement (Nm) Q P c c Cutting speed () Depth o cut (mm) per revolution () Metal removal rate (cm 3 /min) Speciic cutting orce or chip thickness = 0.4 mm (N/mm 2 ) K c0.4 per revolution () Entering angle (degree) Power requirement (kw) Spindle speed (rev/min) D m l m n n n Q n κ r P c n = n = T = π x D m x n x πx D m l m n x n 2 R t = n x 125 rε Q = x x n P c = Q x K c x ( ) n x sin κ r c = x P c πx n Customer Service - Tel.: +33 (0) Fax: +33 (0)

PRIMARY GRADES TURNING TURNING / INSERTS / INTRODUCTION TO CARBIDE INSERTS

PRIMARY GRADES TURNING TURNING / INSERTS / INTRODUCTION TO CARBIDE INSERTS / ISERTS / ITRODUCTIO TO CARBIDE ISERTS PRIMARY GRADES group PVD Coated grades Carbide CVD Ceramics CB PCD Uncoated grades Carbide Cermet P M K S H P01 P05 P10 P15 P20 P25 P30 P35 P40 P45 P50 M01 M05 M15