CA6535. Milling of Heat Resistant Alloy. New Grades CA6535 (CVD) PR1535 (PVD) for a variety of workpiece materials and applications

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Augustus Watts
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1 Milling of Heat Resistant Alloy New Grades for a variety of workpiece materials and applications (CVD) for Nibase heat resistant alloy and martensitic stainless steel (PVD) for titanium alloy and precipitation hardened stainless steel

New Grades (CVD/PVD) New Grades for Extending Tool Life when machining heat resistant alloy and difficulttocut materials (CVD) for

$grades for difficulttocut material Stable cutting prevents insert fracturing Good for high efficiency machining For Nibase heat$ thin film coating technology TiN Smooth & less adhesion AIO3 Oxidation and wear resistant Special Interlayer Prevent peeling of coating

thin film coating technology TiN Smooth & less adhesion AIO3 Oxidation and wear resistant Special Interlayer Prevent peeling of coating

hardened stainless steel Stabilized milling operation and long tool life with Kyocera's MEGACOAT NANO coating technology Improved

2 New Grades (CVD/PVD) New Grades for Extending Tool Life when machining heat resistant alloy and difficulttocut materials (CVD) for Nibase heat resistant alloy and martensitic stainless steel (PVD) for titanium alloy and precipitation hardened stainless steel New grades for difficulttocut material Stable cutting prevents insert fracturing Good for high efficiency machining For Nibase heat resistant alloy and martensitic stainless steel High heat resistance and wear resistance with CVD coating Improved stability due to thin film coating technology TiN Smooth & less adhesion AIO3 Oxidation and wear resistant Special Interlayer Prevent peeling of coating layer TiCN Frictional wear resistant Newly Developed Tougher Substrate MEGACOAT Layer structure For titanium alloy and precipitation hardened stainless steel Stabilized milling operation and long tool life with Kyocera's MEGACOAT NANO coating technology Improved stability due to thin film coating technology Tool Life Comparison Nibase Heat Resistant Alloy st recommendation GM chipbreaker st recommendation SM chipbreaker

RAD8 (MRW High Efficiency Radius Cutter with Multiple Edges) RAD8 (MRW) 3 4 Economical 8edge insert Combined sharpness & cutting edge strength Improved edge strength due to obtuse edge Helical

ØA T Ød W r PR55 PR50 ROMU 04M0ERGM 0.47 0.87 0.8 0.465 0.36 605M0ERGM 0.630 0.6 0.44 0.6 0.35 ROMU 04M0ERSM 0.47 0.87 0.8 0.465 0.36 Low Cutting Force 605M0ERSM 0.630 0.6 0.44 0.6 0.35 ROMU 04M0ERGH 0.

00 50~450~600 SUS304 0.004~0.006~0.008 35~55~650 GM SUS403 0.004~0.006~0.008 500~650~85 0.004~0.006~0.008 0.004~0.008~0.0 SM GH D 605M0ERGH 0.630 0.6 0.44 0.6 0.35 400~600~85 35~500~650 0.004~0.006~0.00 Ni 0.

00~0.004~0.006 Ti6Al4V 0.00~0.004~0.006 5~00~85 0.006~0.0~0.04 400~600~85 0.006~0.0~0.04 35~55~75 0.006~0.008~0.

3 RAD8 (MRW High Efficiency Radius Cutter with Multiple Edges) RAD8 (MRW) 3 4 Economical 8edge insert Combined sharpness & cutting edge strength Improved edge strength due to obtuse edge Helical cutting edge design with maximum axial rake Lower cutting forces equivalent to positive inserts Flat Lock Structure to hold insert firmly Insert Description Dimension (inch) MEGACOAT NANO CVD Coating ØA T Ød W r PR55 PR50 ROMU 04M0ERGM M0ERGM ROMU 04M0ERSM Low Cutting Force 605M0ERSM ROMU 04M0ERGH Tough Edge (Heavy Milling) Stock Standard Chipbreaker Workpiece Material fz (ipt) feed MEGACOAT NANO CVD PR55 PR ~0.008~ ~600~ ~0.008~0.0 35~55~ ~0.006~ ~450~600 SUS ~0.006~ ~55~650 GM SUS ~0.006~ ~650~ ~0.006~ ~0.008~0.0 SM GH D 605M0ERGH ~600~85 35~500~ ~0.006~0.00 Ni 0.004~0.005~ ~00~50 Ti6Al4V 0.004~0.005~ ~50~5 0.00~0.006~ ~600~ ~0.006~ ~55~ ~0.005~ ~450~ ~0.005~ ~55~ ~0.005~ ~0.005~ ~00~50 Ni 0.00~0.004~0.006 Ti6Al4V 0.00~0.004~ ~00~ ~0.0~ ~600~ ~0.0~ ~55~ ~0.008~0.0 50~450~ ~0.0~ ~600~85 D 0.006~0.008~0.0 35~500~650 The figure in bold font is center value of the recommended cutting conditions. Adjust the cutting speed and the feed rate within the above conditions according to the actual machining situation. Machining with coolant is recommended for Nibase Heat Resistant Alloy and Titanium Alloy Recommended feed rate is the reference value when ap is r/ (3mm for ROMU, 4mm for ROMU6). :st Recommendation :nd Recommendation 3

MFour (MEW Double Side, 4Edge Inserts) MFour (MEW) Form Improves Function Kyocera s unique insertforming technology reduces cutting forces equivalent to positive inserts MEGACOAT NANO Extended tool

03 Low Cutting Forces LOMU 50504ERGM 0.06 50508ERGM 0.03 505ERGM 0.047 LOMU 50508ERSM 0.

MEW03R~MEW050R PR55 PR50 0.00~0.004~0.008 0.003~0.006~0.00 400~600~85 0.00~0.004~0.006 0.003~0.006~0.008 0.00~0.003~0.005 0.003~0.005~0.

4 MFour (MEW Double Side, 4Edge Inserts) MFour (MEW) Form Improves Function Kyocera s unique insertforming technology reduces cutting forces equivalent to positive inserts MEGACOAT NANO Extended tool life by new MEGACOAT NANO insert coating technology reduces cutting costs Insert Description r MEGACOAT NANO CVD Coating PR55 PR50 LOMU 00404ERGM ERGM ERGM LOMU 00408ERSM 0.03 Low Cutting Forces LOMU 50504ERGM ERGM ERGM LOMU 50508ERSM 0.03 Low Cutting Forces Chipbreaker GM SM Workpiece Material SUS004 etc SUS600 etc D fz (ipt) feed Stock Standard World Express Toolholder Descriptions MEGACOAT NANO CVD MEW6~MEW8 MEW65~MEW50 MEW03R~MEW050R PR55 PR ~0.004~ ~0.006~ ~600~ ~0.004~ ~0.006~ ~0.003~ ~0.005~ ~0.003~ ~0.005~ ~0.003~ ~0.005~ ~0.003~ ~0.005~ ~55~ ~650~85 000~400~500 35~55~75 50~450~600 35~55~ ~0.004~ ~0.007~ ~0.003~ ~0.006~0.008 Ni 0.00~0.003~ ~0.005~0.006 Ti6Al4V SUS004 etc SUS600 etc 0.00~0.003~ ~0.006~ ~00~65 5~00~ ~0.004~ ~0.006~ ~0.003~ ~0.005~ ~0.003~ ~0.004~ ~0.003~ ~0.004~ ~0.003~ ~0.004~ ~0.003~ ~0.004~0.006 Ni 0.00~0.003~ ~0.004~0.005 Ti6Al4V 0.00~0.003~ ~0.005~ ~55~ ~650~85 65~00~65 5~00~85 600~800~ ~600~85 35~500~ ~600~85 35~55~75 50~450~600 35~55~650 00~65~30 65~00~65 600~800~000 00~65~30 65~00~65 The figure in bold font is center value of the recommended cutting conditions. Adjust the cutting speed and the feed rate within the above conditions according to the actual machining situation. Machining with coolant is recommended for Nibase Heat Resistant Alloy and Titanium Alloy :st Recommendation :nd Recommendation 4

MSix (MFWN 90 Cutter with Double Sided, 6Edge Inserts) MSix (MFWN) Economical 6Edge insert Low cutting forces with less chattering MEGACOAT NANO Extended tool life by new MEGACOAT NANO insert coating

Material fz (ipt) feed GM SM GL D WNEU 080608ENGL 0.004~0.008~0.0 0.004~0.008~0.0 0.004~0.006~0.00 0.004~0.006~0.00 Stock Standard World Express MEGACOAT NANO CVD PR55 PR50 35~500~650 400~600~85 35~55~75 50~450~600 0.

00~0.005~0.008 0.00~0.005~0.008 75~00~50 0.00~0.005~0.008 400~600~85 0.00~0.003~0.006 35~500~650 Ni 0.00~0.004~0.006 Ti6Al4V D 0.00~0.003~0.006 5~00~85 75~00~50 0.00~0.005~0.008 400~600~85 0.00~0.005~0.008 35~55~75 0.

5 MSix (MFWN 90 Cutter with Double Sided, 6Edge Inserts) MSix (MFWN) Economical 6Edge insert Low cutting forces with less chattering MEGACOAT NANO Extended tool life by new MEGACOAT NANO insert coating technology reduces cutting costs Insert Description MEGACOAT NANO CVD Coating PR55 PR50 WNMU ENGM Low Cutting Forces ENSM SurfaceFinish Oriented (High Precision) Chipbreaker Workpiece Material fz (ipt) feed GM SM GL D WNEU ENGL 0.004~0.008~ ~0.008~ ~0.006~ ~0.006~0.00 Stock Standard World Express MEGACOAT NANO CVD PR55 PR50 35~500~ ~600~85 35~55~75 50~450~ ~0.006~ ~0.006~ ~0.008~ ~0.005~ ~600~85 35~500~650 Ni 0.004~0.005~0.008 D 0.00~0.005~ ~0.005~ ~0.003~ ~0.005~ ~500~ ~600~85 35~55~75 50~450~ ~0.005~ ~0.005~ ~00~ ~0.005~ ~600~ ~0.003~ ~500~650 Ni 0.00~0.004~0.006 Ti6Al4V D 0.00~0.003~ ~00~85 75~00~ ~0.005~ ~600~ ~0.005~ ~55~ ~0.003~ ~450~ ~0.005~ ~500~ ~0.005~ ~0.005~ ~0.005~ ~600~ ~0.003~ ~500~650 Ni 0.00~0.004~ ~00~50 Ti6Al4V 0.00~0.003~ ~00~85 The figure in bold font is center value of the recommended cutting conditions. Adjust the cutting speed and the feed rate within the above conditions according to the actual machining situation. Machining with coolant is recommended for Nibase Heat Resistant Alloy and Titanium Alloy :st Recommendation :nd Recommendation 5

MFPN High Efficiency Face Mill MFPN 0edge Pentagonal Inserts for roughing and generalpurpose face milling 3 Low Cutting Forces with helical cuttingedge design Fractures Suppressed by doubleedge

06 High Precision (Finishing) Chipbreaker Workpiece Material fz (ipt) feed Stock Standard World Express MEGACOAT NANO CVD 6 GM D 0.004~0.008~0.06 0.004~0.008~0.06 0.004~0.008~0.04 0.004~0.008~0.06 PR55 PR50 35~500~650 400~600~85 35~55~75 50~450~600 0.

00~0.005~0.00 35~500~650 SM 0.00~0.005~0.00 0.00~0.005~0.00 0.00~0.005~0.00 400~600~85 D 0.00~0.004~0.008 35~500~650 Ni 0.00~0.004~0.006 75~00~50 Ti6Al4V 0.00~0.003~0.006 5~00~85 0.00~0.005~0.00 400~600~85 0.

6 MFPN High Efficiency Face Mill MFPN 0edge Pentagonal Inserts for roughing and generalpurpose face milling 3 Low Cutting Forces with helical cuttingedge design Fractures Suppressed by doubleedge design Insert Description Dimmension (in) MEGACOAT NANO MEGACOAT CVD A T Ød X Z PR55 PR50 PR5 PR0 PNMU 05ANERGM Low Cutting Force 05ANERSM 0.44 PNEU 05ANERGL High Precision (Finishing) Chipbreaker Workpiece Material fz (ipt) feed Stock Standard World Express MEGACOAT NANO CVD 6 GM D 0.004~0.008~ ~0.008~ ~0.008~ ~0.008~0.06 PR55 PR50 35~500~ ~600~85 35~55~75 50~450~ ~0.008~ ~0.008~ ~0.008~ ~0.008~ ~600~85 35~500~650 Ni 0.004~0.005~ ~00~ ~0.005~ ~600~ ~0.005~ ~55~ ~0.004~ ~450~ ~0.005~ ~500~650 SM 0.00~0.005~ ~0.005~ ~0.005~ ~600~85 D 0.00~0.004~ ~500~650 Ni 0.00~0.004~ ~00~50 Ti6Al4V 0.00~0.003~ ~00~ ~0.005~ ~600~ ~0.005~ ~55~ ~0.004~ ~450~ ~0.005~ ~500~650 GL 0.00~0.005~ ~0.005~ ~0.005~ ~600~85 D 0.00~0.004~ ~500~650 Ni 0.00~0.004~ ~00~50 Ti6Al4V 0.00~0.003~ ~00~85 The figure in bold font is center value of the recommended cutting conditions. Adjust the cutting speed and the feed rate within the above conditions according to the actual machining situation. Machining with coolant is recommended for Nibase Heat Resistant Alloy and Titanium Alloy :st Recommendation :nd Recommendation

MEC Low Cutting Force with sharp cutting performance 3 Perfect 90 Shoulders with smooth surface of shoulder wall Extensive Grade Lineup Applicable to a wide range of workpiece materials, such as

008 T304ERJT 0.06 T308ERJT 0.03 T3ERJT 0.047 0.64 0.50 0.0 0.433 8 3 T36ERJT 0.063 T30ERJT 0.079 T34ERJT 0.095 T33ERJT 0. BDMT 70404ERJT 0.06 70408ERJT 0.03 704ERJT 0.047 7046ERJT 0.063 0.378 0.93 0.

03 fz (ipt) feed Stock Standard World Express Toolholder Descriptions MEGACOAT NANO CVD MEC0500~MEC0750 MEC000~MEC500 MEC500R~MEC4000R PR55 PR50 0.00~0.004~0.006 0.003~0.006~0.00 400~600~85 0.00~0.004~0.005 0.

7 MEC Low Cutting Force with sharp cutting performance 3 Perfect 90 Shoulders with smooth surface of shoulder wall Extensive Grade Lineup Applicable to a wide range of workpiece materials, such as steel, stainless steel, cast iron, and aluminum Insert Chipbreaker JT JS Workpiece Material D Description Dimmension (in) Angle ( ) MEGACOAT NANO CVD Coating A T Ød W r PR55 PR50 BDMT T30ERJT T304ERJT 0.06 T308ERJT 0.03 T3ERJT T36ERJT T30ERJT T34ERJT T33ERJT 0. BDMT 70404ERJT ERJT ERJT ERJT ERJT ERJT ERJT ERJT 0.58 BDMT T30ERJS T304ERJS T308ERJS 0.03 BDMT 70404ERJS ERJS 0.03 fz (ipt) feed Stock Standard World Express Toolholder Descriptions MEGACOAT NANO CVD MEC0500~MEC0750 MEC000~MEC500 MEC500R~MEC4000R PR55 PR ~0.004~ ~0.006~ ~600~ ~0.004~ ~0.006~ ~0.003~ ~0.005~ ~0.003~ ~0.005~ ~0.003~ ~0.005~ ~0.003~ ~0.005~ ~55~ ~650~85 35~55~75 50~450~600 35~55~ ~0.004~ ~0.007~ ~0.003~ ~0.006~0.008 Ni 0.00~0.003~ ~0.005~0.006 Ti6Al4V 0.00~0.003~ ~0.006~ ~00~50 5~00~ ~0.004~ ~0.006~ ~0.003~ ~0.005~ ~0.003~ ~0.004~ ~0.003~ ~0.004~ ~0.003~ ~0.004~ ~0.003~ ~0.004~0.005 Ni 0.00~0.003~ ~0.004~0.005 Ti6Al4V 0.00~0.003~ ~0.004~ ~55~ ~650~85 75~00~50 5~00~50 400~600~85 35~500~650 The figure in bold font is center value of the recommended cutting conditions. Adjust the cutting speed and the feed rate within the above conditions according to the actual machining situation. Machining with coolant is recommended for Nibase Heat Resistant Alloy and Titanium Alloy :st Recommendation :nd Recommendation 400~600~85 35~55~75 50~450~600 35~55~650 00~50~5 75~00~50 75~00~50 7

Case Studies MRW Cr Steel Cr Steel Turbine Blade Vc=875sfm fz=0.006ipt ap=0.00~0.039 ae=max.378 Dry MRW050R6TM (6 inserts) ROMU04M0ERSM ().

8 Wet MRW050R5TM (6 inserts) ROMU04M0ERSM () Same or longer tool life Economical doublefaced insert Stable Machining Stable, Available for Further Machining Competitor A

MRW has a cost advantage due to double sided inserts. Competitor B (Positive Cutter) Unstable Machining MRW showed less damage on the cutting edge and reduced cutting noise.

0 Wet MFPN4560R8T (8 inserts) PNMU05ANERSM () Heat Resistant Alloy Turbine Blade Vc=55sfm fz=0.005ipt ap=0.

5 Surfaces/Corner or Cutting Edge Competitor D (Positive Cutter) 4 Surfaces/Corner or Cutting Edge MFPN processed the same number of output as Competitor D.

5 Surfaces/Corner or Cutting Edge MFPN achieved.4 times longer tool life compared with Competitor E with stable machining. MFWN SUS36L Energy Plant Part Vc=500sfm fz=0.

8 Case Studies MRW Cr Steel Cr Steel Turbine Blade Vc=875sfm fz=0.006ipt ap=0.00~0.039 ae=max.378 Dry MRW050R6TM (6 inserts) ROMU04M0ERSM (). times the machining efficiency Economical doublefaced insert Turbine Blade Vc=85sfm fz=0.006ipt ap=0.079 ae=0.97~.8 Wet MRW050R5TM (6 inserts) ROMU04M0ERSM () Same or longer tool life Economical doublefaced insert Stable Machining Stable, Available for Further Machining Competitor A (Positive Cutter) Unstable Machining MRW improved machining efficiency. times with same tool life compared to Competitor A. MRW has a cost advantage due to double sided inserts. Competitor B (Positive Cutter) Unstable Machining MRW showed less damage on the cutting edge and reduced cutting noise. MRW has equal or longer tool life and cost advantage due to doublesided inserts. MFPN Ti6AI4V Chemical Plant Part Vc=85sfm fz=0.08ipt ap=0.0 Wet MFPN4560R8T (8 inserts) PNMU05ANERSM () Heat Resistant Alloy Turbine Blade Vc=55sfm fz=0.005ipt ap=0.079 Wet MFPN4500R8T (8 inserts) PNMU05ANERGM () 4 Surfaces/Corner or Cutting Edge 3.5 Surfaces/Corner or Cutting Edge Competitor D (Positive Cutter) 4 Surfaces/Corner or Cutting Edge MFPN processed the same number of output as Competitor D. Edge condition was still possible to extend tool life. MFPN has cost advantage due to 0edge use compared with Competitor D (4edge) Competitor L (Positive Cutter).5 Surfaces/Corner or Cutting Edge MFPN achieved.4 times longer tool life compared with Competitor E with stable machining. MFWN SUS36L Energy Plant Part Vc=500sfm fz=0.006ipt ap=0.8~0.97 Wet MFWN9060R8T (8 inserts) WNMU080608ENGM () Competitor C (Negative Cutter) Surface/Corner or Cutting Edge Surface/Corner or Cutting pcedge MFWN improved cutting edge condition and finished surface compared with Competitor C. Kyocera Industrial Ceramics Corp. Cutting Tool Division 00 Industrial Park Road Hendersonville, NC cuttingtools@kyocera.com Website: Distributor Website: Customer Service: Option Technical Support: Option c o n n e c t w i t h u s