CBN / Diamond Coated Carbide

Transcription

1 CBN / Diamond Coated Carbide

2 CBN CBN Style Applications Typical parts Turning hardened steel Single or Multi tipped Multi tipped Rough & Finish turning gray iron Hardened steel (Continuous - Interruption) Hardened steel (Interruption) Brake disks & drums Cylinder liners Gears Shafts Gears Shafts is a solid PVD coated CBN grade with a high CBN content. An increased CBN content and a binder high in binding force, 's main range application is cast iron machining. Notch wear resistance Breakage resistance General applications Cutting speed (SFM) Rough turning Finish turning is a CBN grade which has the combined toughness and wear resistance needed for high performance hard turning steel applications. is available in petite (single use) sizes but with multitipped cutting edges. is a special ceramic bonded CBN grade. has the combined toughness and thermal shock resistance needed for interrupted hard turning applications. SPEED (sfm) & HARDNESS (Rc) Case Study Brake disk (Rough) Longer tool life Gear (61-65RC) Constant tool life Gray cast iron Insert SNM SFM 08 IPR.00" DOC With coolant 510H Insert CNGA3 30 SFM.006 IPR.00" DOC No coolant Heavily Interrupted NTK : 800 pcs/edge NTK : 50 pcs/edge CBN 650 pcs/edge CBN 0-50 pcs/edge 106

3 CCMW CCMW 1.51 P 1.5 P For details of boring bars, see page 168. CCMW 0600 P P 09T30 09T308 Stock 1 1 1/ 1/ 3/8 3/8 3/3 3/3 5/3 5/3 1/6 1/3 1/6 1/3 weeks delivery CNGA / CNMA CNGA 31 CNMA 31 CNGA 3 CNMA 3 33 PQ PQ PQ CNGA 100 PQ CNMA 100 CNGA 1008 PQ CNMA PQ For details of toolholders, see pages 11 and 18. Stock 1/6 1/ 3/16 1/3 3/6 weeks delivery DNGA / DNMA DNGA 31 PQ DNGA 1500 PQ DNMA 31 DNMA 1500 DNGA 3 PQ DNGA PQ DNMA 3 DNMA PQ 1501 PQ For details of toolholders, see pages 1, 13 and 18. Stock 1/6 1/ 3/16 1/3 3/6 weeks delivery RNM RNM S TN 3S TN RNMN S TN 3S TN 1/ 1/8 3/16 Edge prep: TN is T05 Stock weeks delivery For details of toolholders, see page

4 CBN SNM SNM 3S TNB 33S TN S TN 3S TN 3S TN 33S TNF 3S TNF SNMN 3S TNB 33S TN S TN 3S TN 3S TN 33S TNF 3S TNF Edge prep: TNB is T05, TN is T05, TNF is T085 Stock weeks delivery For details of toolholders, see pages 117, 118, 15 and 19. SNGA / SNMA 3/8 1/ 1/8 1/8 3/16 1/3 3/6 1/3 3/6 1/3 3/6 1/16 SNGA 3 PE SNGA 1008 PE SNMA 3 PQ SNMA 1008 PQ 33 PE PQ 101 PE PQ For details of toolholders, see pages 15 and 19. Stock 8 8 1/3 1/ 3/16 3/6 weeks delivery TCMW TCMW 1.51 P TCMW 1100 P 1 1/ 3/3 1/6 For details of boring bars, see page 169. Stock weeks delivery TNM TNM 3S TNC TNMN 3S TNC 33S TN 33S TN 333S TNF 333S TNF 1/ 3/8 1/8 3/6 1/3 3/16 3/6 Edge prep: TN or TNC is T05, TNF is T085 Stock weeks delivery For details of toolholders, see pages 16 and

5 TNGA / TNMA TNGA 331 PH TNMA 331 PT TNGA 33 PH TNMA 33 PT 333 PH PT For details of toolholders, see pages 16 and 17. TNGA 1600 PH TNMA 1600 PT TNGA PH TNMA PT 1601 PH PT Stock /6 3/8 3/16 1/3 3/6 weeks delivery TPM TPM 31 PT 3 PT TPMN PT PT 3 3 3/8 1/8 1/6 1/3 Stock weeks delivery VNGA / VNMA VNGA 331 PQ VNGA 1600 PQ VNMA 331 VNMA 1600 VNGA 33 PQ VNGA PQ VNMA 33 VNMA For details of toolholders, see pages 13 and 1. Stock 1/6 3/8 3/16 1/3 weeks delivery 109

6 Diamond Coated Carbide Diamond Coated UC Best Performance for Al alloy (High Si Al alloy), MMC(FRM) Ceramics, Reinforced ceramics, Carbon Features Improvement in Wear Resistance Superior wear resistance designed for hard-to-cut aluminum material i.e. High Si Al alloy and MMC material. Physical Performance Crystal structure UC Natural diamond DLC PCD Diamond Diamond Amorphous Diamond Composition of Diamond Coating Bonded phase Density(g/cm 3 ) Young's modulus(gpa) Hardness(GPa) None None None Co, Ni, etc Fine and thick diamond layer has improved wear resistance performance. Special surface treatment has improved spalling resistance performance. Variety in Shapes Moulded chipbreakers ensure better chip control. UC inserts have a deeper cutting potential due to the coating covering the whole cutting edge. Types of shapes Lower Cost Available in multi cornered geometries and no re-grinding cost. Effective cutting-edge area Note: The line indicates an effective cutting-edge area. Without chipbreaker Cost reduction by switching to multi-corner type UC PCD(Brazed with sintered diamond) Characteristics of UC has well-balanced durability against spalling and abrasion. 110

7 Boring of Al Alloy Part number Competitor's PCD (Sintered diamond) Brazed cutter UC SPMW09031 (-corner type) Cutting speed 600m/min Feed rate 0.mm/rev Cutting depth.0 mm (Total) Coolant WET Tool life 3,000 pcs/cornerr 6,000 pcs/corner Part name Hub of Motor-bike Aluminum alloy UC with a molded chipbreaker breaks up the chips to a manageable size. The operator has to stop the machine in remove the chips when using the PCD insert. Chips by PCD Scale: 0." Chips by UC Scale: 0." Outer Roughing of Al Alloys Part number Competitor's PCD (Sintered diamond) Brazed cutter UC SPMW09031 (-corner type) Cutting speed 600m/min Feed rate 0.mm/rev Cutting depth.0 mm (Total) Coolant WET Tool life 3,000 pcs/corner 6,000 pcs/corner Part name Piston Aluminum alloy(al+13vol%si) UC doubled tool life over the PCD. Productivity was improved. Although the PCD can be re-ground eight times, UC allowed a cost reduction by extending the life of the tool and using a four-cornered insert. Rough Boring of Al Alloys Part number Competitor's PCD (Sintered diamond) TPGW11030 (1 cutting edge) UC Special shape ( cutting edges) Cutting speed 8000m/min -1 Feed rate 0.15mm/rev Cutting depth 3.0mm Coolant WET Tool life 1 pc/corner 8,000 pcs/corner Part name Piston Aluminum alloy(al+13vol%si) The competitor's PCD insert cannot machine a single part because of chatter and the brazed tip coming off. The long effective cutting-edge on the UC inserts can take deeper cuts, and its chipbreaker eliminated chatter. 111

8 Diamond Coated Carbide Ceramics Outer Diameter Finishing Part number Competitor's PCD (Sintered diamond) Brazed cutter (w/out chipbreaker) UC VNMM1600- (-corner, w/molded chipbreaker) Cutting speed 150m/min Feed rate 0.mm/rev Cutting depth 8.0mm Coolant DRY Tool life 300 pcs/corner 00 pcs/corner Part name Vacuum switch parts Ceramic calcined body The life of UC can be extended to 1.3 times that of a competitor's PCD tool, thus allowing productivity to be correspondingly improved. UC insert can cut to greater depths than conventional PCD tools. This features requires less insert changes. Aluminum Alloy Plunge Cutting Part number Carbide Special shape UC BSMN307Z (Formed insert) Cutting speed 18m/min Feed rate 0.06mm/rev Cutting depth 3.0mm Coolant WET Tool life 5,000 pcs/corner 50,000 pcs/cornerr Part name Two-wheel cylinder, mouth-chamfered Aluminum alloy(al+1vol%si) Carbide inserts caused too much build-up edge which resulted in insert failure. UC has excellent build-up edge resistance. UC comes in a variety of shapes and can extend tool life 10 times vs. carbide inserts. 11

9 Standard Stock Shape UC Screw Wrench CNMM 31 CNMM 100 TNMM 331 TNMM 1600 VNMM 331 VNMM 1600 CCMT 1.51 CCMT 0600 LRIS.57 RLR 15S Without chipbreaker CCMT 3.51 CCMT 3.5 DCMT 3.51 SPM 1 CCMT 09T30 CCMT DCMT 11T30 SPMN 1030 LRIS 6 LRIS 8 LLR 5S SPMR 1 SPMR 1030 TCMT 1.51L TCMT 1.5L TCMT 1100L TCMT 11008L Wiper TCMT 1.51 WL TCMT 1100 WL LRIS.57 RLR 15S TPMT 1L TPMT L TPMT 11030L TPMT L TPMR 1L TPMR 11030L TPMR 31 TPMR TPMP 631L TPMH 0800L LR S. LR S 5.5 RLR-13S TPMT 631L TPMT 0800L TPMP 731L TPMH 0900L LR S.5.8 LR S.56 RLR 15S TPMH 1L TPMH 11030L LR S 36. LR S 37.8 RLR 0S TPMH 31L TPMH 16030L LR S 5.8 LR S 9 RLR 0S Wiper TPMT 631 WL TPMT 0800 WL RPMX MO GB RPMX 103 MO GB VCMT 1 VCMT LRIS.57 RLR 15S weeks delivery 113

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