Coated Carbide for Highly Stable Cast Iron Machining

Transcription

1 CA3-Series CVD Coated Carbide for Cast Iron Coated Carbide for Highly Stable Cast Iron Machining Improved Coating Adhesion Prevents Chipping and Provides Stable Machining Micro TiCN Coating Provides Excellent Wear Resistance Unique Insert Grades for Various Cast Iron Machining Applications ( / / ) KQ Chipbreaker Cast Iron Machining Chipbreaker K-Series KH Chipbreaker KG Chipbreaker

2 CA3-Series Coated Carbide for Highly Stable Cast Iron Machining CA3-Series Coated Carbides Launched New Coated Carbide Grades CA3-Series for Reliable & Efficient Cast Iron Turning Prevents Adhesion due to Specialized Post-coating Hard Surface Layer Provides advanced wear resistance High-Performance α-al2o3 Layer Excellent Wear and Chipping Resistance Strong Intra-coating Adhesion Higher adhesion between each layer with improved crystal structure Micro TiCN Layer Higher coating hardness is possible due to a micro TiCN crystal structure, resulting in increased wear resistance 1 High Coating Adhesion Results in Stable Machining Strong Intra-coating Adhesion Rake Face Condition (In-house Evaluation) Micro Intra-coating Structure Higher adhesion by increasing bonding surface with aluminum oxide layer Impact-Resistant Intra-coating Structure Interface strength is increased by 20% (compared to our products), which resists boundary destruction CA3-Series () Competitor A Cutting Conditions: Vc = 490 sfm, D.O.C. = 0.059", f = ipr, Wet, CNMG432 Type, Facing, (After Withstanding 3,000 Impacts) Workpiece: (8 Grooves in Workpiece) 2 Micro TiCN Coating Provides Excellent Wear Resistance Maximized Layer Structure (Pattern diagram) Coating Hardness Comparison (In-house Evaluation) Al₂O₃ Layer TiCN Layer Maximized Layer Structure TiCN Coating Strength 20% Coating Hardness CA3-Series Conventional CA3-Series Conventional A 2

3 3 Unique Insert Grades For Various Cast Iron Machining Applications Gray Cast Iron - First Recommendation Nodular Cast Iron - First Recommendation Wear Resistance Conventional K05 Grade First Recommendation Conventional K15 Grade Wear Resistance Conventional K05 Grade First Recommendation Conventional K15 Grade Stability Conventional K20 Grade Stability Conventional K20 Grade Gray Cast Iron (First Recommendation) Grade for high-speed continuous machining and improved tool life through the deposition of a thickened alumina coating layer. For finishing to roughing of gray cast iron. Wear Resistance Comparison (In-house Evaluation) Wear Amount (in) Competitor B Machining Duration: About 7.4 Minutes Competitor B Cutting Time (min) Cutting Conditions: Vc = 980 sfm, D.O.C. = 0.059", f = ipr, Wet CNMG432 Type Workpiece: Nodular Cast Iron (First Recommendation) For continuous to interrupted machining with a good balance of wear resistance and stability Excellent performance for machining gray and nodular cast iron by optimizing the total coating layer thickness High efficiency and long tool life Fracture Resistance Comparison (In-house Evaluation) 1st 2nd 1st Competitor A 2nd 0 2,000 4,000 6,000 8,000 Number of Impacts Cutting Conditions: Vc = 660 sfm, D.O.C. = 0.059", f = ipr, Wet CNMG432 Type Workpiece: (8 Grooves in Workpiece) Interruption Evaluation: 2 Times For Interrupted Machining Fracture Resistance Comparison (In-house Evaluation) Improved stability with CVD layer structure with high adhesion Long tool life for nodular cast iron during heavily interrupted or high-speed machining Competitor C 1st 2nd 1st 2nd 0 5,000 10,000 15,000 20,000 25,000 Number of Impacts Cutting Conditions: Vc = 490 sfm, D.O.C. = 0.059", f = ipr, Wet CNMG432 Type Workpiece: (8 Grooves in Workpiece) Interruption Evaluation: 2 Times 3

4 4 CA3 for Cast Iron Machining with New K-Series Chipbreakers Great for a Large Range of Heavy Machining Operations due to Improved Chipping Resistance Recommended K-Series Chipbreakers Heavy Interruption First Recommendation KH Chipbreaker For Interruption to Heavy Interruption With Scale Heavily Interrupted First Recommendation KH Chipbreaker (For Interruption to Heavy Interruption) Good for Heavily Interrupted Machining Focus on High Stability with Flat Land Interruption Light interruption KG Chipbreaker For Continuous to Interruption Continuous Long Workpiece Improved Locating / Seating in the Toolholder Pocket Resists Vibration and Edge Location Movement Continuous KQ Chipbreaker Sharpness Focused Thin-walled Material High Precision Unstable Machining Low Rigidity Material and Low Clamping Force Stable Machining High Rigidity Material and High Clamping Force Flat Land Tough and Reliable Edge Security High Feed to Heavily Interrupted Machining First Recommended Edge Preparation with Breakage Resistance KQ Chipbreaker (Sharpness Focused) Good for Machining when Sharpness is Necessary Such as Thin-walled Material Good Balance of Low Cutting Forces and Edge Strength KG Chipbreaker (for Continuous to Interruption) For Various Cast Iron Machining Applications Chipping Resistance is Improved Despite Having a Positive Land Improved Locating / Seating in the Toolholder Pocket Resists Machining Vibration Improved Locating / Seating in the Toolholder Pocket Resists machining vibration and great for a wide variety of machining operations Balance of Sharpness and Strength Edge Geometry is Appropriate for Thin-walled Workpieces Positive Land Excellent Balance of Sharpness and Strength Machining from Continuous to Interruption 4

5 Negative Inserts Sharp Edge Finishing- / with Wiper Edge CNMG 432KH 433KH 3/64 Þ Þ Þ CNMG 431KQ 434KH 1/16 Þ Þ Þ 432KQ CNMG 431KG 433KQ 3/64 Þ Þ Þ 432KG CNMG 432WQ 433KG 3/64 Þ Þ Þ 433WQ 3/64 Þ Þ Þ CNMG /16 Þ Þ Þ CNMG 543 3/64 Þ Þ Þ 5/8 1/ /16 Þ Þ Þ CNMG /4 1/ /64 Þ Þ Þ 644 1/16 Þ Þ Þ CNMG 432PH Sharp Edge DNMG 432KH 433KH 3/64 Þ Þ Þ DNMG 442KH 443KH 3/64 Þ Þ Þ DNMG 431KG 432KG DNMG 441KG 433KG 3/64 Þ Þ Þ 442KG 443KG 3/64 Þ Þ Þ DNMG 431KQ 432KQ DNMG 441KQ 442KQ DNMG 431 DNMG /64 Þ Þ Þ DNMG 432PH 433PH 3/64 Þ Þ Þ DNMG 442PH 443PH 3/64 Þ Þ Þ DNMG 431C 432C 433PH 3/64 Þ Þ Þ 434PH 1/16 Þ Þ Þ CNMG 543PH 3/64 Þ Þ Þ 5/8 1/ PH 1/16 Þ Þ Þ CNMG 431C 432C 433C 3/64 Þ Þ Þ 434C 1/16 Þ Þ Þ CNMG 543C 5/8 1/ /64 Þ Þ Þ CNMG 432ZS CNMG 432GC CNMA ZS 3/64 Þ Þ Þ 433GC 3/64 Þ Þ Þ /16 Þ Þ Þ - DNMG 441C 433C 3/64 Þ Þ Þ 442C 443C 3/64 Þ Þ Þ DNMG 432ZS 433ZS 3/64 Þ Þ Þ DNMG 442ZS 443ZS 3/64 Þ Þ Þ DNMG 432GC 433GC 3/64 Þ Þ Þ DNMG 442GC 443GC 3/64 Þ Þ Þ DNMA DNMA RNMG 43 - Þ Þ Þ RNMG 54 5/8 1/ Þ Þ Þ Þ : U.S. Stock 5

6 Negative Inserts SNMG 432KH TNMG 332KH 433KH 3/64 Þ Þ Þ 333KH 3/64 Þ Þ Þ 434KH 1/16 Þ Þ Þ SNMG 432KG 334KH 1/16 Þ Þ Þ TNMG 331KG 332KG 433KG 3/64 Þ Þ Þ 333KG 3/64 Þ Þ Þ SNMG 322 3/8 1/ SNMG /64 Þ Þ Þ 434 1/16 Þ Þ Þ Sharp Edge TNMG 331KQ 332KQ TNMG /64 Þ Þ Þ SNMG 432PH /64 Þ Þ Þ 433PH 3/64 Þ Þ Þ 434PH 1/16 Þ Þ Þ SNMG 543PH 3/64 Þ Þ Þ 5/8 1/ PH 1/16 Þ Þ Þ 334 1/16 Þ Þ Þ 335 5/64 Þ Þ Þ TNMG SNMG 432C TNMG 332PH 433C 3/64 Þ Þ Þ 333PH 3/64 Þ Þ Þ SNMG 432ZS TNMG 331C 332C 433ZS 3/64 Þ Þ Þ 333C 3/64 Þ Þ Þ SNMG 432GC 433GC 3/64 Þ Þ Þ SNMA 431 TNMG 332ZS 333ZS 3/64 Þ Þ Þ 432 TNMG 332GC 433 3/64 Þ Þ Þ 434 1/16 Þ Þ Þ 435 5/64 Þ Þ Þ SNM GC 3/64 Þ Þ Þ TNMA /2 3/ /64 Þ Þ Þ 334 1/16 Þ Þ Þ 335 5/64 Þ Þ Þ Þ : U.S. Stock 6

7 Negative Inserts Positive Inserts Relief Angle VNMG 332KH CCMT 2151GK 1/4 3/ /64 Þ Þ Þ CCMT 3251GK 3/8 5/ /64 Þ Þ Þ 333KH 3/64 Þ Þ Þ VNMG 332KG Finishing- CCMT 431GK 1/2 3/ GK 333KG 3/64 Þ Þ Þ CCMT /8 5/ /32 Þ Þ Þ VNMG WNMG 432KH 433KH 3/64 Þ Þ Þ 434KH 1/16 Þ Þ Þ WNMG 431KG 432KG Finishing- CPMH /16 3/ CPMH 321 3/8 1/ DCMT 2151GK 1/4 3/ GK DCMT 3251GK 3/8 5/ GK 433KG 3/64 Þ Þ Þ WNMG 431KQ DCMT /8 5/ /32 Þ Þ Þ 432KQ Sharp Edge 433KQ 3/64 Þ Þ Þ WNMG 431 RCMX 1204M / Þ Þ Þ 432 WNMG 432PH 433PH 3/64 Þ Þ Þ WNMG 431C SPM 421 1/2 1/8-422 SPM 432 1/2 3/16 - TCMT 2151HQ 1/4 3/ HQ 432C 433C 3/64 Þ Þ Þ WNMG 432ZS Finishing- TCMT 3252HQ 3/8 5/ HQ 3/64 Þ Þ Þ TPMT 221HQ 1/4 1/ HQ 433ZS 3/64 Þ Þ Þ WNMG 432GC 433GC 3/64 Þ Þ Þ WNMA 432 Finishing- TPMT 321HQ 3/8 1/ HQ TPMR 221 1/4 1/8-222 TPMR 321 3/8 1/8-322 TPM 221 1/4 1/8-222 TPM /8 1/8-1/32 Þ Þ Þ 323 3/64 Þ Þ Þ Þ : U.S. Stock 7

8 Case Studies Differential Gear Case FCD450 Vc = 1,080-1,310 sfm D.O.C. = f = ipr Wet CNMG433KH () Differential Gear Case FCD660 Vc = 590 sfm D.O.C. = f = ipr Wet WNMG433KH () 100 pcs /edge x2 20 pcs /edge x2 Competitor D (Molded Chipbreaker) 50 pcs /edge Competitor E (Molded Chipbreaker) 10 pcs /edge KH Chipbreaker doubled tool life compared to competitor D. Competitor E s insert broke after machining 10 pieces but with KH Chipbreaker doubled tool life without insert breakage. (User Evaluation) (User Evaluation) Flywheel Gray Cast Iron Vc = 980 sfm D.O.C. = f = ipr Dry WNMG433KH () Heavy Interruption Disc Nodular Cast Iron Vc = 460 sfm D.O.C. = f = ipr Wet CNMG433KH () Ø9.8 Ø24.8 Ø pcs /edge x2 10 pcs/edge x1.4 Competitor F (Molded Chipbreaker) 50 pcs /edge Competitor G (Molded Chipbreaker) 7 pcs/edge Competitor F shows unstable tool life with insert breakage when machining over 50 pieces/edge but provides stable tool life while machining over 100 pieces/edge. achieves 1.4 times the tool life of competitor G. (User Evaluation) (User Evaluation) KYOCERA Precision Tools, Inc. 102 Industrial Park Road Hendersonville, NC Customer Service Option 1 Technical Support Option 2 Official Website Distributor Website mykpti.kyocera.com cuttingtools@kyocera.com KYOCERA Precision Tools, Inc. 11/16 5K Printed in the U.S.A.