SUMIDIA / SUMIDIA Binderless SUMICRYSTAL

Transcription

1 SUIDIA / SUIDIA Binderless 152 Grade SUIDIA Series... 2 SUIDIA Binderless... 4 SUIDIA... 6 Inserts SUIDIA Break aster LD Type / GD Type... 7 SUIDIA Break aster D Type... 8 SUIDIA Inserts Identification... 9 SUIDIA Indexable Inserts Sck List... 1 SUIDIA Binderless Indexable Inserts Sck List Holders Expanded SEC-Wide Tool Holders SGW Type SUIDIA ini Boring Bars CKB Type SUIDIA Small Hole Boring Bars DABB Type Cutters / Endmills Drills Expanded Expanded High Efficiency Cutters For Aluminum Alloy HF Type... 3 High Speed Cutters For Aluminum Alloy RF Type Small Diameter Cutters For Aluminum Alloy SRF Type SUIDIA Cutters FA Type / SA Type... 4 SUIDIA Cutters SA-E Type SUIDIA ini-cutters DFE Type SUIDIA Binderless Endmills NPDRS Type / NPDBS Type / NPDB Type SUIDIA Endmills DFE Type SUIDIA Endmills DAE Type SUIDIA Drills DAL Type SUIDIA Drills DDL Type SUIDIA SUIDIA SUIDIA Binderless 5 UP 51 PD / PDX 52 Sck Indications and Symbols mark : Standard scked item mark: To be replaced with the new item featured on the same page mark: To be replaced by new item (Please confirm sck availability) * mark: Semi-standard sck (Please confirm sck availability) mark: Sck or planned sck (Please confirm sck availability) No mark: ade--order item mark: We cannot produce 1

2 Polycrystalline Diamond Tools SUIDIA Series General Features SUIDIA is a polycrystalline diamond material developed by using our proprietary technologies. SUIDIA is available in 4 grades (,, DA22 and ), each having different characteristics depending on the size of the diamond grains and the combination of binder materials. In addition, a new grade () made by nano-level diamond grains without binder material with direct conversion sintering has been newly added our product line. SUIDIA can be used for all types of applications, from machining aluminum alloys brittle materials such as carbide. Grades / Features / Applications Grade Features Applications Average Size of Hardness HV diamond Grains (μm) (GPa) TRS (GPa) SUIDIA Binderless A 1% diamond grade made by nanolevel diamond grains with direct conversion sintering. Has the highest wear resistance and fracture resistance, and the best edge sharpness. Surface finishing of carbide achining brittle materials (ceramics) up ade by sintering super fine-grained diamond at high densities. Has excellent wear resistance, fracture resistance, and edge sharpness. High silicon aluminum alloy machining Rough machining / interrupted machining / surface finishing of aluminum alloys Woodworking, cutting / face machining of wood and wooden boards General surface finishing of non-ferrous metals up SUIDIA DA22 ade by sintering super fine-grained diamond. Has a good balance of wear resistance and fracture resistance, and has excellent edge sharpness. A grade made by sintering fine-grained diamond. Diamond grains are firmly joined gether. Has an excellent balance of machinability and wear resistance. Rough machining / interrupted machining / surface finishing of aluminum alloys Woodworking, cutting / face machining of wood and wooden boards General surface finishing of non-ferrous metals Surface finishing of pre-sintered ceramic parts and stamped parts achining FRP, hard rubber, and carbon Cutting/face machining of wooden and inorganic boards A grade made by sintering rough-grained diamond. Contains the highest amount of diamond. Has excellent wear resistance. High silicon aluminum alloy machining achining of aluminum composite materials Rough machining of carbide, pre-sintered ceramic parts, and stamped parts. achining of sintered ceramic parts, machining of sne / rock up Cutting Performance Al-25% Si alloy continuous cut test results C (Al-2% SiC) continuous cut test results Carbide (87HRA) continuous cut test results Competir.3 SUIDIA SUIDIA SUIDIA Binderless Frank Wear Width (mm) Competir A Cutting distance (km) Competir B Work material: Al-25% Si alloy Insert: SPGN1234 Holder: FP11R Cutting conditions: v c = 5 m/min, f =.1 mm/rev, a p =.2 mm, Dry Frank Wear Width (mm) Cutting distance (km) Work material: C (Al-2% SiC) Insert: CNX1248 Holder: PCLN2525 Cutting conditions: v c = 35 m/min, f =.2 mm/rev, a p =.18 mm, Wet Frank Wear Width (mm).2.1 VB=.171mm VB=.34mm Cutting distance (km) Work material: Carbide (87HRA) Insert: DCW11T34RH Holder: SDJC22 Cutting conditions: v c = 2 m/min, f =.1 mm/rev, a p =.1 mm, Dry 2

3 Polycrystalline Diamond Tools SUIDIA Series Application Range Aluminum achinability Good Work material Sintered aluminum Die cast aluminum (ADC12) Low silicon (AC2B-T6,AC4C-T6) High silicon (T6) Turning Roughing DA22 Finishing illing Example part Cylinder liner Transmission case, oil pan cylinder block, aluminum wheel, HDD Cylinder head Cylinder block Recommended Cutting Conditions Work material Aluminum alloy Copper alloy Reinforced plastic Wood, inorganic board (Cutting, etc.) Cutting speed v c (m/min) up 3, up 1, up 1, up 4, Carbide 1 3 Carbon 1 6 Feed rate f (mm/rev) up.2 up.2 up.4 up.4 up.2 Depth of cut a p (mm) up 3 up 3 up 2 up.5 1 up 2 Difficult Non-aluminum achinability Work material Roughing Turning Finishing illing Example part Good Non-ferrous sintered alloy Bushing DA22 Gunmetal carbon Connecting rod Carbide Punches, dies, rolls Iron combined Cylinder block, bearing cap Difficult SUIDIA Grinding ethod Grinder Griding Wheel Category Abrasive grain Diamond Detail (1) It is desirable use a specialized high rigidity grinder. (2) Wet grinding must be used. Grain size Rough grinding: 4 mesh Finish grinding: 8 1,5 mesh Bond Concentration Vitrified, or metal bond specialized for polycrystalline diamond ols Dressing Dress with a stick that is approximately 4 mesh WA Peripheral Speed 8 1, m/min Grinding Table Rocking 3 6 rev/min conditions Grinding fluid Water soluble grinding fluid (solution type) Other (1) The rake surface is generally lapped. (2) Inspect for edge chipping using a microscope with a magnification of 3 5 times. (3) achining of non-ferrous metals require a sharp cutting edge. (4) Surfaces that were cut by ED should have more than mm ground off. Note: Contact us for re-grinding. SUIDIA SUIDIA SUIDIA Binderless 3

4 SUIDIA Binderless Nano-Polycrystalline Diamond General Features Nano-polycrystalline diamond is a type of polycrystalline diamond, produced by directly binding nano-level diamond grains without using any binders. This material is unique our company, and as compared conventional diamond grades containing binders, it exhibits higher strength, excellent wear resistance and fracture resistance. SUIDIA Binderless is the series of ols with cutting edges made from this high performance nano-polycrystalline diamond. icro-structure Comparison Hardness Nano-polycrystalline diamond SE structure Conventional PCD SE structure BinderCo Nano-polycrystalline diamond No anisotropy and high hardness Single crystal diamond Hardness depends on crystal orientation Conventional PCD Load 4.9 N Diamond particle average grain diameter (3 5 nm) Diamond particle average grain diameter (1 1 µm) 5 1 Knoop hardness Hk (GPa) 15 Application Examples SUIDIA Binderless Ballnose Endmill / Radius Endmill (Carbide achining) 43 Indexable Inserts (Carbide achining) 26 SUIDIA SUIDIA SUIDIA Binderless Drills (Ceramics Drilling) Cutting Tool (Ultra-precision Cutting of Carbide) 4

5 SUIDIA Binderless General Features By using nano-polycrystalline diamond for the cutting edge, these ols achieve excellent wear resistance and fracture resistance compared ols made with previous polycrystalline diamond. In particular, nano-polycrystalline diamond makes it possible achieve improved machining accuracy and long ol life for machining brittle materials such as carbide, etc. Characteristics Best suited for high precision machining of carbide Achieves high precision machining of carbide with nano-polycrystalline diamond, which has excellent wear resistance. aintain excellent dimensional accuracy over long periods Greatly reduces the number of times that the ol must be replaced compared previous diamond ols, improving work efficiency and reducing tal cost. Applicable machining brittle materials akes it possible perform turning on brittle materials (ceramics, etc.) that could previously only be machined through grinding. Applicable Range (Carbide achining) 1. Hardness less than 88 HRA 2. Hardness 88 HRA or more.2.2 Depth of cut ap (mm) Depth of cut ap (mm).2 Feed rate f (mm/rev).2 Feed rate f (mm/rev) Recommended Cutting Conditions (Carbide achining) Work material Cutting conditions Class Hardness (HRA) SEI Grades Cutting speed v c (m/min) Feed rate f (mm/rev) Depth of cut a p (mm/rev) V 7 VC or more and less than 88 V VC 4 88 or more achining Accuracy External Turning of Carbide VC5 (87HRA) Dimension variation (mm) Conventional grade Cutting distance (m) G7 G6 G5 D2 3mm ø5mm has no dimension variation even with cutting distance of 45 m. Lower limit value - recommended value - upper limit value Cutting oil: Dry Boring of Carbide V 3 (91HRA) Dimension variation (mm).8.6 Conventional grade , 1,2 Cutting distance (m) 3mm ø26mm has no dimension variation even with cutting distance of 1,1 m. SUIDIA SUIDIA SUIDIA Binderless Work material: Carbide VC5 (87HRA) Insert: DCW11T34RH Cutting conditions: v c = 2 m/min, f =.1 mm/rev, a p =.1 mm, Dry Work material: Carbide V3 (91HRA) Insert: DCW11T34RH Cutting conditions: v c = 2 m/min, f = mm/rev, a p = mm, Dry 5

6 SUIDIA Characteristics High-density sintered ultra-fine diamond particles Significantly improved surface roughness on the machined surface World's best wear resistance and strength Achieves high performance, high precision, and high efficiency machining of all aluminum alloys and non-ferrous alloys. Positioning Cutting Performance Excellent Transverse GPa DA22 Improved wear resistance Improved fracture resistance Wear resistance in turning application Flank wear mm Conventional grade 2 4 Cutting distance (km) Work material: 17% Si-Al alloy Insert: TPGN 1634 Conditions: vc = 8 m/min f =.12 mm/rev a p =.5 mm Wet 6 Excellent finished surface Cutting edge ridge is smooth Work material: 17% Si-Al alloy Insert: TPGW 1638 Conditions: vc = 1, m/min, f = mm/rev, ap =.2 mm Wet Conventional grade Rough finished surface Ridge is rough 1m Wear resistance Excellent NF Inserts SUIDIA NF inserts preserve the excellent basic performance of while achieving high cost performance through optimal design and development of mass production technology. These inserts achieve the high performance of SUIDIA, including excellent fracture resistance, wear resistance, and smooth work material surface finishing. NF insert cutting edge SE image (NF insert cutting edges have surfaces finished by precision grinding, just as the conventional products) SUIDIA SUIDIA SUIDIA Binderless Application Examples Total cost effectiveness with high cutting performance and lower price Reasonable prices are achieved through optimal design and development of mass production technologies. Can also handle re-grinding, greatly reducing tal cost. illing of aluminum alloy oil pump cover Results: Tool life was 1.5 times that of our competirs PCD. Good performance at low cost. NF inserts Other Companies PCD 1 2 Tool life ratio Finishing of aluminum alloy valve bore New product line including a wide range of ols, from general turning ols milling ols A wide range of ols are kept in sck, including ols for small hole boring, external turning, and milling. Negative-positive type inserts, which can be used as is with standard lever lock and pin lock holders, are also kept in sck. Results: Achieved a ol life of 5 times that of cemented carbide without initial fracturing. NF inserts Carbide 1 5 Tool life ratio Work material: ADC12 Insert: NF-TEEN32R Cutting conditions: vc = 3, m/min, f Z =.6 mm/t, ap =.2 mm, Wet Work material: ADC12 Insert: NF-TPGN1134P Cutting conditions: vc = 53 m/min, f = mm/rev, ap =.2 mm, Wet 6

7 SUIDIA Inserts With Chipbreaker SUIDIA Break aster LD Type / GD Type Chraracteristics Achieves outstanding chip control in medium cutting - finishing of aluminum alloy. Enables substantial improvement in work efficiency by resolving chip control problems. Has stable and long ol life by using grade with high hardness Wrought Aluminum alloy (A661) Cast Aluminum alloy (ADC12) Depth of cut ap (mm) GD Type Depth of cut ap (mm) GD Type LD Type Feed rate f (mm/rev) LD Type Feed rate f (mm/rev) LD Type Chipbreaker for Finishing Excellent chip control in the finishing process GD Type Chipbreaker for edium Finishing Excellent chip control in the medium finishing process Cutting Performance Wrought aluminum alloy machining Process: Boring of machine parts Cutting Performance Cast aluminum alloy machining Process: Boring of transmission parts Good chip control during low depth cutting of wrought materials Finely fragments chips during machining of cast materials SUIDIA SUIDIA SUIDIA Binderless Break aster LD Type Without chipbreaker Break aster GD Type Without chipbreaker Work material: A661 Insert: NF-VCT1132N-LD () Cutting conditions: vc = 2 m/min f =.2 mm/rev ap = mm Wet Work material: ADC12 Insert: NF-TPT1134N-GD () Cutting conditions: vc = 4 m/min f =.23 mm/rev ap = 1.2 mm Wet Warning: Re-grinding this product may affect the chip control performance. 7

8 One Use Inserts With Chipbreaker SUIDIA Break aster D Type Chraracteristics Economic one use type One Use Inserts, familiar users of the SUIBORON series, are now available in SUIDIA. Entrust chip control cutting edges with chipbreakers. Eliminates chip control trouble through the effect of D type chipbreakers. Substantially improves work efficiency. Application Range For internal machining Feed rate (mm/rev) Chip control effect region Depth of cut (mm) (Work material: ADC12 Internal machining, wet) For external machining and face machining (Insert shape: 55/8Diamond) Chip Control Performance Chips from Break aster D Type Chips from an insert without a chipbreaker Feed rate (mm/rev) Chip control effect region Application Example achining details Cutting conditions Results SUIDIA SUIDIA SUIDIA Binderless Depth of cut (mm) (Work material: ADC12 External machining, wet) Recommended Cutting Conditions Internal machining (Insert shape: Triangular type) Feed rate f Depth of cut a p Style up mm/rev up.7 mm Wet External copying (Insert shape: 55/8Diamond) Feed rate f Depth of cut a p Style up mm/rev up.5 mm Wet Boring Series Lineup achining details Boring External/Face machining Unit compatible Holder compatible Work material: AC2A-T6 v c = 3 m/min f =.6 mm/rev a p =.35 mm Wet NU-TPR113 type NU-TPR163 type NU-TPT82 type NU-TPT92 type NU-TPT112 type NU-TPT113 type Generated good, curled chips with a length of approximately 2mm without leaving any chips in the work material while fulfilling the requirement that the finished surface roughness be Ra=1 μm or less. NU-CCT62 type NU-CCT9T3 type NU-DCT72 type NU-DCT11T3 type For face machining, use a depth of cut.4 mm or less. NU-TPT164 type 8

9 SEC- Inserts Identification Regrindable Type CNA 1248 B Insert ISO code ISO Standard Classification) B2/B3 Supplementary symbol Chart 1 Chart 1: Supplementary symbol Symbol R L B WF RH Right hand Left hand Description Entire cutting face PCD type Cutting edge with special land for aluminum wheel gloss finishing Honing specification (Treated cutting edge) One corner type NF - CNA 1248 P Type Chart 2 Insert ISO code ISO Standard Classification) B2/B3 Supplementary Symbol Chart 3 Chart 2 Type Symbol Description NF NF inserts 6 NU One use inserts Chart 3 Supplementary symbol Symbol Description L Left hand P Full length cutting edge type N-LD N-GD Chipbreaker type (Neutral) 7 R-D Chipbreaker type (Right handed) 8 L-D Chipbreaker type (Left handed) 8 Insert shape All-PCD Surface type Cutting edge with special land for aluminum wheel glassy finishing NF insert One use inserts Full length cutting edge type Chipbreaker type SUIDIA SUIDIA SUIDIA Binderless 9