Alro Steel. Pre-hardened Steel 45 HRC with ESR Properties

Transcription

1 Alro Steel Metals Industrial Supplies Plastics Toolox 44 Pre-hardened Steel 45 HRC with ESR Properties Toolox 44 is a highly engineered quench & tempered pre-hardened tool and machine steel with measured and guaranteed mechanical properties. Toolox 44 is delivered ready to use, no heat treating required, saving you valuable production time, reducing risks and lowering overall costs. Product Features Quench and tempered steel Ready to use, no additional heat treatment required Easy to machine with good dimensional stability High strength and toughness at elevated temperatures Double the toughness of comparable steels at the same hardness Excellent for etching, polishing and EDM Low residual stress, no stress relieving required Excellent substrate for surface treatments Supplied as (HR) plate, thickness 1 to 5-1/8 Applications Cold Work Tooling Machine Components Wear Components Guide Rails Plastic Molds Rubber Molds Press Forming Forging Dies Die Cast Dies alro.com ALRO

2 Characteristics & Advantages Toolox is a steel with ESR properties. The CSR casting process together with the low carbon concept gives a high degree of cleanliness and a homogenious structure. Fundamental factors to provide you with an excellent substrate for machining, polishing, texturing and EDM. Homogeneity & low levels of inclusions Without CSR With CSR The fundamental idea behind Toolox is to deliver a steel that is hardened and ready for use, with tested and guaranteed physical properties. Thanks to CSR method of casting we get homogeneity and cleanliness at the same level as in ESR re-melted material. Every plate is uniquely produced. Toughness By working with a low carbon concept and a very high cooling rate, we have produced a steel that is two to three times tougher than comparable steels of similar hardness. The high hardness, in combination with excellent toughness, ensures lower tool wear and high levels of output when the tool is in service. Modified Carbide Morphology With high cooling rate during quenching and a low carbide concept we have been able to modify the carbide morphology. This is the base for the high toughness. Fatigue Toolox has unique toughness and fatigue properties, which remarkably increase the lifespan of the tool or machine component. Thanks to its ultra-high cleanliness, the surface and not the steel is the critical question for the fatigue properties. High Temperature Properties Toolox 44 has high strength and toughness at elevated temperatures, even with extended contact times. This heat resistance makes Toolox 44 excellent for tools and components working at high temperature. Physical Properties +20 o C +200 o C +300 o C +400 o C +500 o C Heat conductivity (W/m*K) Thermal expansion coefficient (10-5 /K)

3 Characteristics & Advantages Low Residual Stress Toolox is delivered in a quenched and tempered condition. The high tempering temperature gives very low residual stress levels. Even after heavy machining Toolox does not require stress relieving. Etching, Polishing & EDM Thanks to the advanced CSR casting technology, Toolox is effectively free of segregation and has a very high level of cleanliness. This makes Toolox excellent for etching and polishing, and the EDM process works with no problems at all. Welding & Gas Cutting Chemical composition Toolox 44 C Si Mn P S Cr Mo V Ni CEIIW CET 0.32% % 0.8% Max 0.010% Max 0.002% 1.35% 0.80% 0.14% Max 1.0% The effective quenching used when producing Toolox gives the possibility to use a low alloy content compared to regular tool and machine steel. This gives Toolox better weldability and makes it easier to cut. Mechanical Properties Hardness (HBW) Hardness (HRC) Yield Strength R P0.2 (MPa) Tensile Strength R M (MPa) Elongation, A5, (%) Impact toughness, Charpy-V (J) +20 o C 450 ~45 1,300 1, o C 1,150 1, o C 1, o C 1, o C 930 Inclusions Toolox 44 Inclusion size (equivalent dia.) Area fraction Aspect ratio 6 micron 0.015% 1.2 alro.com ALRO

4 Machining Recommendations Despite a hardness of 45 HRC, Toolox 44 is easily machined. Toolox is based on a low carbon concept, with low carbide content. Carbides are hard to machine, the low carbide content is the reason for the excellent machinability. Clamping Toolox has a very low level of residual stresses. To get the full effect make sure to use deformation-free clamping. If blanks are gas cut, mill off 5-10mm from the gas-cut edge to get a blank free from residual stresses. The machinability of Toolox has been improved. During milling you will notice it because the chips produced are very bluish. We have modified the carbide morphology as compared to traditional tool steels, using less carbon in Toolox. Therefore, the heat generated during milling is transferred into the chip and not into the cutting edge/workpiece. Milling Advice Position the cutter off-center (to the left) to achieve a thicker chip at the entry and to avoid thick chip on the exit. Avoid cutting through the center line of the cutter, because this could generate vibration. Always use down milling (climb milling). The recommendation is that the radial engagement of the cutter (ae) should be 25 or 75-80% of the diameter. If you enter the workpiece with the roll-into-cut method, the chip thickness on the exit is always zero, and it will help to give a longer tool life. Roll-into-cut method D Prog. rad. = ( e ) Rolling into cut method Wear after 800 passes Straight into the workpiece Wear after 390 passes 2 mm V f V f

5 Drilling & Tapping Recommendations Use only HSS drills when you have unstable machine conditions. If the machine conditions are good you can use different solid/brazed cemented carbide drill or drills with exchangeable heads. HSS-Co HSS HSS-E HSS-Co Use an HSS-Co drill (8% Co) with a low helix angle and a robust core that can withstand high torques. Individual holes can be drilled with an ordinary HSS drill. For a rational production, either a microalloyed (HSS-E) or a Cobalt alloyed (HSS- Co) drill is recommended. Individual holes can be drilled with an ordinary HSS drill. For a rational production, either a microalloyed (HSS-E) or a Cobalt alloyed (HSS-Co) drill is recommended. Metric (mm) Toolox 44 V c m/min ~7 Dc (mm) *35 *40 Feed rate (mm/min) & speed (rpm) 0.05/ / / / / / / /55 *When using a large drill diameter (>30 mm) make sure that: 1. The machine is large and stable enough to raise sectinal forces. 2. The spindle has zero play. 3. The workpiece is clamped. 4. Motor output is equal to or greater than 7.5 kw. With the correct tools you can perform all tapping/thread milling operations using all Toolox grades. We recommend four-flute taps, which can withstand the very high torque that occurs during tapping in hard materials. If is not critical, the drilled hole can be 3% larger than standard. This will increase the lifetime of the tap. * Thread oil or thread paste is recommended as lubricant. * We recommend thread milling for thread below M5 Countersinking and counterboring are best performed using tools that have replaceable inserts. Always use a revolving pilot and use coolant. Tap for blind holes. Tap for through holes. Metric (mm) Toolox 44 V c (m/min) 3-5 Size M5 M6 M8 M10 M12 M16 M20 Speed (rpm) Metric (mm) Toolox 44 V c (m/min) Feedrate mm/rev Dc (mm) Speed (rpm)

6 Your One Stop Shop for Metals, Industrial Supplies & Plastics About Alro Processing Services Integrity. Loyalty. Honesty. These principals have guided Alro Steel since our founding in 1948 by brothers, Al and Robert Glick. From a small garage in Jackson, Michigan, Alro Steel has grown to over 60 locations in 12 states. Alro distributes metals, industrial supplies and plastics. A wide variety of processing services are available including cutto-size metals and plastics with next day delivery to over 25,000 customers in North America. Saw Cutting Production/Precision Sawing Plate Sawing Focused on exceeding our customers expectations, we build relationships with all our customers, large and small. To learn more, visit alro.com. Tube Laser Cutting Plate Laser Cutting Plasma Cutting Metals Shearing Plate Grinding Super SquarePrecision Milling Alloy Aluminum Brass Bronze Carbon Steel Cast Iron Copper Stainless Tool Steel Bar Abrasives Brushes Coolant Cutting Tools Die Supplies Pipe Tube Plate Sheet Structural Industrial Supplies Gaging Grinding Hand Tools Machinery Maintenance Grating Exp. Metal Material Handling MRO Supplies Sanding Tool Holding Work Holding Illinois Aurora Bloomingdale Bolingbrook Chicago Elk Grove Village University Park Waterjet Cutting Wisconsin Milwaukee Oshkosh Indiana Ft. Wayne Indianapolis Muncie Thermal Processing Alpena Ann Arbor Battle Creek Bay City Cadillac Clare Charlotte Michigan Detroit Flint Grand Rapids Grayling Jackson Kalamazoo Lansing Plastic CNC Routing Livonia Madison Heights Niles Potterville Troy Warren New York Buffalo ABS Acetal Acrylic Delrin Extren Fiberglass Grating Plastics Makrolon Nylon Nyloil PEEK Phenolics Plexiglas Polycarbonate Polypropylene PTFE Starboard TIVAR UHMW Urethane Vivak Note: The symbols & indicate a registered trade name. Metals Outlet Alro Metals Outlet locations stock a broad range of metals and plastics in a convenient retail setting. Metals Outlet specializes in small to large orders, perfect for machine shops, do-it-yourself (DIY) and maintenance departments. Oklahoma Tulsa Missouri St. Louis Kentucky Louisville Pennsylvania Philadelphia Pittsburgh York Ohio Akron Columbus Dayton Toledo North Carolina Charlotte Greensboro Florida Boca Raton Clearwater Jacksonville Miami Orlando Pompano Beach Sarasota Tampa alro.com J ALRO