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Technical Information

Speed Chart for Turning


(SFM) MATERIAL HARDNESS HC7 DEPTH B36 HC1 XT3 HC2 ZC4 HC6 T3N XN4 OF B26 HW2 C7X ZC7 CUT 1000 2000 2500 1100 .020 900 1800 2000 950 750 .080 650 .150 880 2000 2500 900 .020 780 1800 2000 800 650 .080 580 .150 800 1800 2000 800 .020 700 1500 1500 700 580 .080 530 .150 700 1500 1800 700 .020 600 1300 1500 600 540 .060 500 .120 600 1500 1500 600 .020 500 1200 1200 500 420 .060 350 .120 550 1200 1200 1200 550 .020 450 1000 1000 1000 450 350 .040 270 .080 450 1000 1000 400 .020 350 800 300 .040 .080 250 600 .010 550 .020 500 .060 500 420 450 .010 450 370 400 .020 340 370 .040 450 350 350 .010 375 300 300 .020 250 250 .040 600 600 .020 500 500 400 .060 350 .120 300 800 .020 700 .040 600 .080 500 500 .010 450 450 .020 400 400 .040 480 400 400 .010 420 350 350 .020 300 300 .040 800 800 630 .020 700 600 .080 550 .150 480 400 400 .010 450 350 350 .020 300 300 .040 900 1000 .020 780 850 550 .040 550 .120 800 850 .020 780 500 .040 500 .120 NOTE:RECOMMENDED STARTING SPEEDS BASED UPON USING CNGA-432 INSERT CHOICE:1st 2nd

130

180

220 CARBON STEEL 260 1000 SERIES ALLOY STEELS 4000 5000 6000 8000 9000 SERIES 300

350

40RC

50RC

60RC

65RC

280

45RC TOOL STEEL 55RC

62RC

BEARING STEEL

200

Technical Information

52100

62RC

STAINLESS STEEL 300 SERIES

160

200

180

(SFM) MATERIAL HARDNESS HC7 DEPTH B36 HC1 SX5 HC2 ZC4 WA1 T3N XT3 XN4 OF B26 HW2 SX9 ZC7 CUT 1000 1100 .020 600 950 160 .040 600 .120 800 850 .020 500 800 200 .040 500 .120 300 900 800 .010 250 800 700 45RC .020 800 .040 250 700 540 450 .010 700 480 400 55RC .020 600 400 .040 700 650 1500 .010 600 1200 .020 .080 350 1000 1200 .020 1000 1200 36RC .040 800 1000 .120 800 1000 .020 750 900 .040 42RC 700 900 .100 800 1000 .020 700 900 .040 40RC 650 850 .100 600 800 .020 600 800 .040 45RC 550 750 .080 600 800 700 .020 600 800 600 .040 45RC 550 750 .080 800 1000 650 .020 800 1000 .040 750 950 .080 650 600 800 1000 .020 600 500 800 1000 .040 800 1000 .120 1000 350 1200 .020 1000 1200 .040 30RC 800 1000 .120 800 250 1000 .020 700 900 .040 40RC 700 900 .120 1000 .020 650 600 800 .040 600 500 800 .080 350 1200 1200 1000 .010 300 1000 1000 800 .020 40RC 800 900 700 .080 725 725 600 .010 600 600 500 .020 55RC 500 500 450 .040 NOTE: RECOMMENDED STARTING SPEEDS BASED UPON USING CNGA-432 INSERT CHOICE:1st 2nd

STAINLESS STEEL 400 SERIES

AM355

INCONEL 718 X750

WASPALOY

RENE 88 INCONEL 713 IN 100 INCONEL 600 SERIES

HASTELOY

K-MONEL

STELLITE

181

Technical Information

Speed Chart for Turning


(SFM) MATERIAL HARDNESS SX1 DEPTH HC1 HC2 XT3 HC6 SX6 SP2 T3N XN4 OF B16 HW2 HC7 Q15 SX8 CUT SE1 700 3000 2000 3000 2000 3000 3000 .020 650 2500 2000 2500 2000 2500 .080 2000 2000 1800 AS CAST 600 2000 1500 2000 1500 2000 2500 .020 500 2000 1500 2000 1500 1500 .080 1500 1500 1500 AS CAST 800 2000 1800 2000 2000 2000 .020 700 2000 1500 2000 1500 1500 .060 2000 2000 1200 AS CAST 600 1500 1500 1500 1800 2000 .020 500 1500 1500 1500 1600 .060 1500 1500 1500 AS CAST 800 1500 1500 1800 .020 650 1500 .060 AS CAST 500 1200 1200 1500 .020 450 1200 .060 AS CAST 1800 1800 1800 .020 1500 1500 .060 1200 1200 AS CAST 1200 1500 1500 .020 1200 1200 .060 1000 1000 AS CAST 600 600 .020 500 500 600 .060 500 500 500 .120 500 .020 500 .040 300 300 400 .080 400 .010 400 .020 350 .040 700 1800 1800 1800 .020 2000 2000 1500 1500 .040 1500 1500 .080 1500 .010 1200 1200 .020 1000 .080 800 1000 .010 700 800 .020 600 .080 650 .010 600 .020 .080 3500 .040 3500 .080 3000 .160 3000 .040 2500 .080 2500 .160 1500 .010 1200 .020 1000 .080 NOTE: RECOMMENDED STARTING SPEEDS BASED UPON USING CNGA-432 INSERT CHOICE:1st 2nd

180 GRAY CAST IRON 230

200 MALLEABLE IRON 250

DUCTILE IRON (NODULAR IRON)

180

250

ALLOY IRON Cylinder Liner Etc.

200

280

65HS CHILLED IRON

75HS

80HS NIRESIST IRON

170

70 POWDER METAL

150

250 ALUMINUM ALLOY Low SI Content NON FERROUS (Copper, Brass) NON METALLICS Nylons, Acrylics

Technical Information
182

(SFM) SX1 DEPTH HC2 SX5 C7X HC6 SX6 WA1 T3N XT3 XN4 OF HC7 SX9 C7Z SX8 CUT 800 700 800 .020 800 650 130 .040 700 600 .120 600 550 700 700 .020 700 CARBON 500 180 .040 600 STEEL 500 .120 550 550 700 700 .020 600 1000 SERIES 500 220 .040 600 500 .120 500 ALLOY 500 600 .020 550 600 STEELS 450 260 .040 500 450 .120 450 4000 450 600 .020 500 600 5000 400 300 .040 450 6000 350 .080 8000 400 500 .020 400 500 9000 350 350 .040 350 SERIES 350 .080 250 400 .010 300 400 250 40RC .020 250 .040 550 .020 600 600 600 550 .040 250 600 500 .120 450 .020 500 500 500 DIE STEEL 400 .040 320 450 400 .080 250 1000 .010 250 400 200 800 .020 45RC 200 .040 .020 1000 .040 160 STAINLESS .120 STEEL .020 850 .040 200 .080 .020 3000 600 1500 1500 700 .060 2500 180 2000 AS CAST GRAY IRON 2500 500 1200 1200 .020 600 2000 .060 230 1500 AS CAST 2000 700 .020 750 DUCTILE 1500 600 .040 180 IRON 1500 500 AS CAST 2500 500 3000 .010 2000 2500 .020 36RC INCONEL 1500 2000 .080 718 2000 400 2500 .010 400 1500 2000 .020 42RC 1500 2000 .040 NOTE: SPEEDS ARE RECOMMENDED AS A STARTING POINT TO BE ADJUSTED ACCORDINGLY. CHOICE:1st 2nd MATERIAL HARDNESS

183

Technical Information

Types, Applications, and Characteristics of NTK Insert Materials Ceramic Series


Physical characteristics NTK Grade Components Applications
Density Hardness Bending Young's Thermal expanHeat strength modulus sion coefficient conductivity

g/cm3 SX1 Silicon-nitride-based SX5 SX6 SX8 SX9 SP2 HC1 HW2 SE1 Alumina-based HC2 ZC4 HC6
Si3N4 SiAlON Si3N4 Si3N4 SiAlON Highly efficient cutting of gray cast iron Ni-based Heat Resistant Alloys Highly efficient cutting of gray cast iron Strong interrupted cutting of gray cast iron Ni-based Heat Resistant Alloys

HRA 93.5 92.5 93.5 93.0 93.5 93.5 94.0 94.0 94.5 94.5 95.5 94.0

MPa 1200 1100 1200 1200 1200 1100 700 750 800 800 1000 800

GPa 320 350 320 320 330 320 400 390 390 420 420 450

X10-6/K W/m-K 3.0 4.0 3.0 3.2 3.0 3.0 7.8 7.8 7.7 7.8 7.8 7.6 29 18 29 33 15 29 17 19 31 21 25 29

3.2 3.6 3.2 3.2 3.3 3.2 4.0 4.1 3.8 4.3 4.6 4.7

TiN-coating Rough turning of gray cast iron + Si3N4 Al2O3 Al2O3 Al2O3 Al2O3 +TiC Semi-finishing and finishing of cast iron Tube scarfing Semi-finishing and finishing of cast iron Liner machining Semi-finishing and finishing of cast iron regardless dry or wet V-pulley Semi-finishing and finishing of cast iron Machining of hardened materials

TiN-coating Machining of hardened materiAl2O3 + TiC als Semi-finishing and finishing of ductile materials TiC + Al2O3 Using Coolant semi-finishing and finishing of cast iron Machining of hardened materials Turning of roll materials Semi-finishing and finishing of cast iron Machining of hardened materials Turning of roll materials Semi-finishing and finishing of cast iron

HC7

Al2O3 +TiC

4.6

95.5

1000

420

7.9

25

ZC7 Whisker-based

TiN-coating Al2O3 + TiC

4.6

95.5

1000

420

7.9

25

WA1

Rough turning of heat-resistant alloys Al2O3 + SiC Highly efficient machining of cast iron Roughing of hardened rolls

3.7

94.5

1200

400

7.6

Technical Information

CBN Series
Ultrahigh-pressure sintered compacts NTK Grade B16 B26 B36 Binder
TiN-coated special ceramics TiN-based Special ceramics

CBN content 82% 65% 65%

Applications
High-speed rough finishing of gray cast iron and rolled materials Continuous and interrupt cutting of sintered steel at middle speed ranges Interrupt cutting of sintered steel at middle speed ranges

Note : Data of coated products relates to the respective base materials. 184

Cermet Series
Physical characteristics NTK Grade Components Applications
Density Hardness Bending Young's Thermal expanHeat strength modulus sion coefficient conductivity

g/cm3 HRA
T3N TiC + TiN TiC + TiN TiN-based TiCN
High-speed finishing of steel Machining of sintered alloys Semi-finishing and finishing of steel General turning of steel Grooving of steel Semi-finishing and finishing of steel Grooving of steel

MPa
1400 1700 1900 1800 1700 1800

GPa
450 450 450 440 450 440

X10-6/K W/m-K
8.3 8.4 8.9 8.2 8.4 8.2 13 21 42 31 21 31

6.0 6.3 5.9 7.0 6.3 7.0

92.7 92.5 91.5 91.5 92.5 91.5

Cermets

XT3 XN4 C7X

PVD coated cermets

Q15 C7Z

High-speed finishing of ductile cast TiCN-coating iron

TiN-coating Boring and grooving of steel

Micrograin Carbide Series


Physical characteristics NTK Grade
Micrograin carbide

Components

Applications

Density Hardness

Bending Young's Thermal expanHeat strength modulus sion coefficient conductivity

g/cm3
KM1 ZM3 QM3 VM1 TAS Micrograin carbide TiN-coating
Turning for aluminum Turning of stainless steel and

HRA
91.0 91.0 91.0 92.0 92.0

MPa
3000 3000 3000 2500 2500

GPa
580 580 580 640 640

X10-6/K W/m-K
5.8 5.8 5.8 5.7 5.7 63 63 63 84 84

14.4 14.4 14.4 14.8 14.8

PVD coated Micrograin carbides

titanium TiCN-coating Continuous/interrupt cutting and milling of steel TiCN-coating Turning of free-cutting steel TiAlN-coating Turning for stainless steel

185

Technical Information

NTK RECOMMENDATION CHART FOR MACHINING

Application Range of NTK Insert Grade


Al2O3 Ceramic HC1 HW2 SE1 Al2O3-TiC Ceramic HC2 ZC4 HC7 / ZC7 TiC Ceramic HC6 Cubic Boron Nitride B16 B26 B36
NEW

Al2O3-SiC Whisker Ceramic WA1 NEW

Si3N4 Ceramic SX1 SX5 SX6 NEW SX8 SX9 CVD Coated Si3N4 Ceramic SP2 CVD Coated Carbide CP7 CP8 PVD Coated Micro Grain Carbide ZM3 QM3 VM1 TAS

Cermet T3N XT3 C7X XN4

NEW

PVD Coated Cermet Q15 C7Z

Low

Cutting speed

High

Micro Grain Carbide KM1

NEW

Low

Feed

High

Technical Information
186

GUIDELINES FOR CERAMIC SUCCESS


Use a Rigid Set-Up.
NTK ceramics work best when both the machine and work piece are secure - eliminate overhang.

Use Sturdy Tooling.


For best results, use toolholders designed for ceramics whenever possible. A top clamp with a pin lock is recommended when using an insert with a hole. Use a mechanical chip breaker if possible. Also, make sure that the insert pocket is clean and burr free.

Use the Largest Insert Size Possible


The strength of Ceramics has increased dramatically over the years, but the fact remains - larger is stronger.

Use Suggested Speeds and Feeds


Avoid dwelling in cuts. Consult charts.

Use a Negative Insert with the Largest Corner Angle.

100

80

60

55

35

STRENGTH INCREASES

Use the Largest Nose Radius Possible


Without Causing Chatter. Usually the stronger the nose radius the longer the tool life. Avoid using 0.4 corner radius inserts.

Use the Largest Lead Angle Possible.


Distributing the workload over a greater area of the cutting edge will prolong tool life.

Use Proper Edge Preparation.


Success with ceramic greatly depends upon the cutting edge. Consult the edge preparation sections for proper specifications.

Use No Coolant with Ceramics Except


Silicon Nitride. If this is not possible then a flooded coolant condition must be used.

Use Ceramics Safely.


Make sure machine operators have adequate training in the use of high speed ceramics. Follow machining parameters with safety in mind at all times.

187

Technical Information

MATERIAL SELECTION FOR MACHINING HIGH TEMPERATURE ALLOYS


Applications Grade Dry Wet Cutting speed (SFM)
150 300 600 900 1200

A
1500 .004 .008

Feed (IPR)
.012 .016 .020 .024 .020

Depth (INCH)
.040 .080 .120 .160

WA1

Rough

SX5 SX9 WA1

Semi-finish
SX9 WA1

Finish

ZM3 QM3 WA1

Grooving
SX5

Applications

Grade Dry Wet

Cutting speed (SFM)


1500 2000 2500 3000 3500 4000 .002

Feed (inch/tooth)
.003 .004 .005 .006 .007 .020

Depth (INCH)
.040 .060 .080 .100

SX5

Milling
SX9

1st choice, 2nd choice Note: Based on using RNG45 insert cutting Inco718

Cutting Speed SFM

1500 1200 900 600 300 0

WA1 SX9 SX5 ZM3,QM3


Continuous Light Interrupted Interrupted

Technical Information
188

Recommended Grades for High Temperature Alloys


Machinability rating and recommended insert grades for machining various High temperature alloys are shown in Table1.

Table1
Rating Work Material Rough Turning Scale 1st SX9 SX5 SX9 SX9 SX9 SX5 SX9 SX9 SX5 SX9 SX9 SX5 2nd SX5 SX9 SX5 SX5 SX5 SX9 SX5 SX5 SX9 SX5 SX5 SX9

B
1.6 0.8 1.8 0.8 1.0 1.0 1.2 1.5 1.0 1.0 0.8 0.8

Rough no scale & semi Finish 1st WA1 WA1 WA1 WA1 WA1 WA1 WA1 WA1 WA1 WA1 WA1 WA1 2nd SX9 SX9 SX9 SX9 SX9 SX9 SX9 SX9 SX9 SX9 SX9 SX9

Grooving 1st WA1 WA1 WA1 WA1 WA1 WA1 WA1 WA1 WA1 WA1 WA1 WA1 2nd SX5 SX5 SX5 SX5 SX5 SX5 SX5 SX5 SX5 SX5 SX5 SX5 1st SX9 SX9 SX9 SX9 SX9 SX9 SX9 SX9 SX9 SX9 SX9 SX9

Milling 2nd SX5 SX5 SX5 SX5 SX5 SX5 SX5 SX5 SX5 SX5 SX5 SX5

Airesist Astrology Hastelloy C Inco625 Inco713 Inco718 Inco738 Inco909 Inco925 Mar M247 Udimet720 Waspaloy

How To Find Recommended Insert Grade


Find recommended insert grade from above Table 1 in consideration of your work material & application. Contact your local NTK representative, if more information is needed.

How To Find Recommended Cutting Speed


1) Find cutting speeds "A" shown in "Grade Selection" on page 188. 2) Find machinability rating "B" of your work material from above Table 1. 3) Find machinability rating "C" of your work hardness from Table 2 below.

Recommendation for Hardness


Table2

HRC (Hardness)

30 1.3

30 1.15

35 1

40 0.85

45 0.7 Technical Information


189

Recommended Cutting Speed


Recommended

Cutting Speed (SFM)

MATERIAL SELECTION FOR MACHINING HIGH TEMPERATURE ALLOYS Application Range For Nickel Based Alloys
Work material : Inco718 no scale Depth of cut : .040 inch Insert : RNG45 Coolant : WET

WA1 Recommended Area


(Fig.1) SFM 2300 WA1 provides superior reliability in both roughing and semi-finishing of nickel based alloys. WA1 is first recomended ceramics for nickel based alloys.

1800

1300

800

500

.004

.008

.012

.016

.020

.024

IPR

SX5 & SX9 Recommended Area


(Fig.2) SFM 2300 SX5 and SX9 do not have the same flank wear resistance as WA1 at high cutting speeds. SX5 and SX9 do have the best toughness and notch wear resistance at high cutting speeds. In order to increase the wear resistance of both SX5 & SX9, the feed must be increased. Increasing the feed utilizes the toughness of SX5 & SX9 gives the user a major advantage of decreasing cycle time.

1800

1300

Technical Information
800

500

.004

.008

.012

.016

.020

.024

IPR

190

How To Reduce Notch Wear


Notching is the main failure when machining nickel based alloys. Notching can be reduced by using proper insert grade, insert shape and re-programing. The following information should help to minimize this problem.

A) Increase cutting speeds for WA1 When the cutting speeds are increased less notch wear is noticeable.
1800 SFM 500 SFM

Shown in Fig.1 on page 190

Shown in Fig.1 on page 190

B) Increase feed rates for SX5 and SX9 Increasing the feed with utilizing the superior toughness of both SX5 & SX9 is effective in reducing notching.
.008 IPR .016IPR

Shown in Fig.2 on page 190

Shown in Fig.2 on page 190

C) Effect of depth of cut Prime consideration should be given to the effect of depth of cut upon insert tool life. There is a direct relationship between the insert radius size and the maximum depth of cut which should be taken. See the chart below for recommendations.
Recommended Depth of Cut Range
ROUND INSERT 1/4" 3/8" 1/2" 1" MAXIMUM D. OF C. .060"...Less .090"...Less .125"...Less .250"...Less

(Fig.3)

*INSERT RADIUS 1/32" 3/64" 1/16" 3/32"

MAXIMUM D. OF C. .008"...Less .012"...Less .016"...Less .024"...Less

*OPTIMUM D. OF C. IS 5-15% OF THE INSERT DIAMETER *BASED ON 0 LEAD ANGLE

191

Technical Information

MATERIAL SELECTION FOR MACHINING HIGH TEMPERATURE ALLOYS


D) Effect of lead angles When cutting nickel based alloys consideration should be given to using the largest lead angle possible. When using large lead angles, the cutting forces are spread over a larger surface area of the insert. This will also improve tool life and surface finish while reducing notching. As the lead angle increases the chip will flow more easily. Typical insert wear pattern showing the effect of various lead angle changes and the resulting increase of depth of cut notching. E) Effect of Ramping
(Fig.5) (Fig.4)

-5

-5

0 15 45

15

45

feed

Notch wear on the insert cutting edge as shown in (Fig. 5) is the result of multiple passes being taken at the same depth of cut. This type of wear will minimize tool life. The following programming examples will help to minimize this mode of failure.

(Fig.6)

feed
Programming "ramping" cuts in the same cutting direction is one of the best procedures to use to minimize notching. By varying the DOC, wear is distributed over the entire cutting edge not on one point.

(Fig.7)

Technical Information

feed

Another programming change that may help to reduce notching is by varying the depth of cut . Again, the same principle applies,notching takes place at various points on the cutting edge rather than concentrated at one point as (Fig.5)

192

How To Reduce Flank Wear


As mentioned earlier, SX5 & SX9 do not have the same flank wear resistance as WA1 at high cutting speeds. Use WA1 for best flank wear resistance needed. Flank wear can be reduced by changing to optimized speeds & feeds for SX5 & SX9.
(Fig.8)

A) Use WA1 Use WA1 where more flank wear resistance needed. B) Increase feed rates for SX5 & SX9 In some case, in order to increase the wear resistance of both SX5 & SX9, the feed must be increased. By increasing the feed and utilizing the toughness of SX5 & SX9, the inserts are off the part sooner causing less wear. Increasing the feed also decreases cycle time and improves productivity and profitability.

Feed rate increased decreases wear amount of SX9


.100 Flank wear (inch) .075 .050 .025 .000 .000 .004 .008 .012 .016 .020 Feed (IPR)
Cutting condition Work material : INCO718 Insert shape : RNG45 Cutting Speed : 800SFM Depth of Cut : .080inch Coolant Whisker rainforced ceramic SX9 Whisker ceramic

SX9

SX9

SX9

SX9

C) Decrease cutting speeds for SX5 & SX9 When the cutting speeds are decreased less flank wear is noticeable.
1300 SFM 500 SFM

Shown in Fig.2 on page 190

Shown in Fig.2 on page 190

How To Eliminate Flaking and Breakage


A) Flaking Flaking on the insert is often caused by too much cutting tool pressure due to increased flank wear or notching. Take a look the failure mode and then refer how to reduce notch wear shown on (page 191) or how to reduce flank wear show on (page193). Also, a slightly larger T-land on the edge prep may help. B) Breakage Insert breakage should be improved by following guidelines. Flaking Breakage
Technical Information

Shown in Fig.1 on page 190

Shown in Fig.2 on page 190

193

MATERIAL SELECTION FOR MACHINING HIGH TEMPERATURE ALLOYS


When the insert breakage happens at the begin of cut scale, it might be caused by too high cutting speeds & feeds.
Knowing the hardness of the work material before the cutting begins may make all the difference between success or failure. Many times on the shop floor the operator does not know the part hardness. If this information is not known then more time is needed in the testing procedure trying to find the optimum speed and feed range. As the material hardness increases speed should decrease. Also, parts that have a forget scale work surface require a 25% speed and feed reduction until the scale is gone. This type of programing change will reduce the potential of notching as a failure mode.
(Fig.9)

f/2

How To Eliminate Chatter


Chatter problems are often caused by too much cutting pressure when machining nickel-based alloys in especially profiling cut or grooving where over hang of holder needed, cutting thin-walled parts or no rigidity machine, and it causes excessive insert wear or insert breakage.
Increase speeds and decrease feeds Use smaller I.C round insert, or smaller nose radius Choose an insert shape with most acute angle possible Use positive insert geometries Reduce lead angle Reduce edge preparation or use sharp edge Minimize overhang

Milling
The dynamic toughness and wear resistance of both SX5 & SX9 grades open up a new frontier in high speed milling of nickel-based alloys. Successful applications include the following : 1) Speed ranges of 2000-3500SFM 2) Feed ranges of ( .003-.006") per tooth 3) No coolant should be used when milling 4) Use RPG-32, RPG-43 or RNG-45 inserts 5) Heavy depth of cuts .040-.0100"

Technical Information
194

MATERIAL SELECTION FOR MACHINING CAST IRONS GUIDELINES FOR SUCCESSFUL MACHINING OF CAST IRONS
No Coolant.
Do not use coolant on heavy interruptions especially at high speeds.

Sand in Castings.
When the scale contains sand, insert failure from depth of cut notching increases. Reduce the lead angle to minimize this problem.

Roughing
When roughing cast iron the nose of the insert must be below the surface scale.

Burrs
When a breakout problem occurs, use a larger nose radius, larger lead angle or decrease the feed rate exiting the workpiece.

Out of Roundness
Out of round cutting conditions cause excessive tool wear. Make sure the insert nose is cutting at all times.

Dwelling
Avoid dwelling in cuts. This will cause premature insert wear.

Turning Gray Cast Iron (HB 180 - 230)


Cutting Condition Roughing-interrupted (as cast) Roughing-continuous (as cast) Finish-interrupted Coolant Finish-continuous NTK Grade Selection Per Speed Range SX8 silicon nitride HC1, HW2 ceramic SE1 ceramic HW2,HC1 ceramic HC2 ceramic SE1, HC6 ceramic (300 - 5000SFM) (1000 - 2500SFM) (500 - 2000SFM) (500 - 3000SFM) (500 - 2000SFM) (500 - 3000SFM) SX1, SX6, SP2 silicon nitride (300 - 5000SFM) SP2, SX1, SX6 silicon nitride (1000 - 3000SFM)

Turning Ductile (Nodular) Cast Iron (HB 180 - 250)


Cutting Condition Roughing-interrupted (as cast) Roughing-continuous (as cast) Finish-interrupted Coolant Finish-continuous NTK Grade Selection Per Speed Range SX8 silicon nitride SX9, SX1, SP2 silicon nitride WA1, SE1 ceramic XT3, Q15 HC6 ceramic SE1 ceramic XT3, Q15 cermet (800 - 1500SFM) (800 - 1500SFM) (500 - 1500SFM) (300 - 800SFM) (500 - 1500SFM) (500 - 1500SFM) (300 - 800SFM)
Technical Information
195

Milling Cast Irons


Cutting Condition Rough-gray-ductile Finish-gray or ductile Coolant NTK Grade Selection Per Speed Range SX1, SX6 silicon nitride SX8 silicon nitride HC6 ceramic (1000 - 3000SFM) (1000 - 2000SFM) (1000 - 1500SFM)

SX1, SX6, SX8 silicon nitride (600 - 3000SFM)

MATERIAL SELECTION FOR MACHINING HARDENED STEELS (50-65RC) HARD TURNING USING HC2, HC7, ZC4 OR ZC7 CERAMIC
GUIDELINES FOR SUCCESS Machine, part & tooling set-up must be rigid minimize overhang. Check speed & feed charts for proper machining parameters. Use proper edge preparation - interrupted cuts may require additional edge preparation. Do not use coolant - if required, have flood condition and keep depth of cut constant. Use positive geometries for close tolerances or thin-walled parts. Qualify parts - hard turning will not correct incoming problems.

RECOMMENDED SPEED CHART


800
SPEED (sfm)

700 600 500 400 300 200 100 0 50 55 60 65 HARDNESS (Rc) 70

RECOMMENDED FEED CHART


NOSE RADIUS 1/64 1/32 3/64 1/16 1/4 D.O.C. (in) .007 .015 .020 .030 .080 FEED (lpr) 30 micro 60 micro .002 - .003 .003 - .004 .003 - .004 .004 - .005 .004 - .005 .005 - .0065 .004 - .0055 .006 - .0075 .007 - .010 .010 - .014

INSTRUCTIONS Speed Chart - Find your part hardness on the scale. Follow the vertical line to your recommended s.f.m. range. Start in the middle. Feed Chart - Find your insert nose radius. Follow the line across to find your maximum depth of cut and feed rates depending upon your surface finish requirements.

Technical Information

HARD TURNING MILL & DIE ROLLS USING HC2 OR HC7 CERAMIC
GUIDELINES FOR SUCCESS When turning mill rolls use insert geometries such as CDH, LNJ, LNM & RCGX. When turning die rolls use insert geometries such as RCGX styles. All of these inserts come with a special edge preparation specifically designed by NTK. Follow the same speed & feed guidelines as described in the preceeding charts. Make sure that the lathe has adequate horsepower to run at the required speed and feed ranges. Rigidity is a prime consideration especially for this type of machining.
196

HARD TURNING WITH B26 & B36 CBN


Hard turning with ceramics is generally more economical than using CBN. For this reason NTK recommends trying ceramic first. Most hard turning applications will be very successful when NTK ceramic is used. Generally, NTK recommends using CBN where there are heavy interruptions in hardened steels (58-65 RC). CBN can withstand greater impacts than ceramics. Also, sharper nose radii can be used because of CBN's higher thermal conductivity characteristic and strength. Both B26 & B36 are available in competitively priced multi-cornered geometries.

HARD TURNING WITH T3N CERMET


Generally speaking, hard turning assumes the workpiece hardness falls within the (58-65 RC) range. When the hardness falls into the (40-50 RC) range NTK T3N cermet material can be successfully used. Since T3N has an extremely small grain size and high hardness, it will offer excellent wear resistance. When machining in the (40-50 RC) range, chip control is usually a concern. This will be no problem because of the NTK's variety of ground chipbreakers available.

Troubleshooting Guide for Hard Turning with NTK Ceramic


PROBLEM Insert wears fast Chattering POSSIBLE CAUSE Speed too high Feed too slow Tool pressure too high Speed too low Set-up not rigid enough Top flaking Insert breakage Speed or feed too high Improper edge preparation Radius too weak Improper edge preparation Coolant (if used) High-micro finish Improper feed rate Insert worn Insert chipped Nose radius too small Erratic tolerances Too much cutting pressure POSSIBLE CORRECTIVE ACTION Consult speed chart Consult feed chart Reduce T-land and use positive insert Increase speed Minimize overhangs and add rigidity Consult speed or feed chart Consult NTK sales office Use larger nose radius Consult NTK sales office Turn off coolant Consult feed chart See above Use larger nose radius Reduce insert radius or chamfer Use positive insert geometry Check rigidity of set-up Heat causes tolerances fluctuations Use coolant make sure that the insert edge is flooded with coolant
197

Technical Information

Replace insert

GUIDELINES FOR CERMET SUCCESS


Use a Rigid Set-Up.
NTK cermets work best when both the machine and work piece are secure - eliminate overhang.

Use Sturdy Tooling.


Use rigid tooling which reduces the chance of chatter. Make sure the insert pocket is clean and burr free. Use a top clamp. Use Largest insert Size Possible.Use Largest Nose Radius Possible Use Largest Lead Angle Possible. Use Cermets to Machine the Following. Carbon Steels Alloy Steels Tools Steels Stainless Steels Powdered Metal Inco 600-700 Series Aluminum (with low Si) Non-Ferrous Materials Non-Metallic Materials

Use Cermets to Machine (HRC 35-50) Materials.


Cermets resist edge deformation and are very wear resistant when machining harder materials.

Use Correct Chipbreaker Design.


Do not curl the chips too tight.Avoid chips from striking the insert or piling up at cutting edge.

Use Light Feeds. Use Suggested Speed Range.


Consult the speed chart for proper speeds cermet speeds increase productivity. Do not exceed .015IPR feed rate. Cermets are more feed sensitive than carbides.

IMPORTANT POINTS TO REMEMBER


Thermal Toughness.
Cermets are more thermal sensitive to coolant than carbides. As a result, rough turning, boring and milling should not be performed using coolant. Conversely, coolant can be used when finish turning or boring. If a cermet insert breaks after machining several parts and coolant is being used, turn off the coolant,replace the cutting edge and start over. Usually, this type of cermet failure is thermal related. The toughness level of cermet materials increases when no coolant is used. Cermets resist cutting edge build-up, so they cut much freer and surface finishes are excellent without the use of coolant. If coolant has to be used, it must be a flooded condition.

Fracture Toughness.
Cermets are best used in semi-finishing and finishing applications. Cermets do not bend - carbides do. Roughing through scaled surfaces are usually best performed by carbides. Cermets can machine parts with interruptions but care must be taken in the form of larger lead angles, stronger insert geometries and larger nose radius. Do not rough any material using a 55 35 or rhomboid cermet insert.

Technical Information
198

MATERIAL SELECTION FOR MACHINING STEELS GUIDELINES FOR SUCCESSFUL USING CERMETS
Tuning Steels.
Using cermets to machine steels provide the user with extended tool life, superior surface finishes and higher productivity through the use of speed. When using cermets to machine steels, feed rates and depth of cuts have to be selected more conservatively than with carbides because of the difference in strength. T3N GRADE DISCUSSION Use this grade when turning (3550Rc) steels. Do not use on iterrupted cuts, only for finish applications. Can be used to mill (40 HRC) die steels. Do not run with coolant, if possible. Use these general purpose grades to finish and semi-finish steels and stainless steels. Use XN4 for the toughest steel applications. Maximum depth of cut -3.5mm. Can be run with or without coolant. Good choice on older machines. (90m/min and up) Use C7X for general purpose milling of steels. Both exhibit excellent shock and wear resistance.

Milling Steels.
The criteria for success when using cermets for milling are two fold ; improved surface finishes and extended tool life. Most successful applications of cermets for milling are with cutters under .250" in diameter.

XT3 -

XN4 -

Consult the "Guidelines for Cermet Success" section for additional information.

C7X -

Carbon and Alloy Steels


Hardness (HB) 130 - 220 Cutting Condition Rough Turning Finish Turning Milling Rough Turning 260 - 300 Finish Turning Milling Rough Turning 300 - 400 Finish Turning Finish-Milling Speed Range 800 - 1200 300 - 650 500 - 800 500 - 800 350 - 580 400 - 550 350 - 600 270 - 420 250 - 400 NTK Grade Selection T3N / XT3 / C7X XN4 / C7X C7X T3N / XT3 / C7X XN4 / C7X C7X T3N XT3 C7X / T3N

Tool Steels
- 45 HRC Finish Turning Finish-Milling 100 - 135 75 - 150 T3N C7X
NOTE - Speeds based upon using a CNGA-432 insert. - Ceramics can be used in machining steels. Consult speed and feed chart. - Mechanical chipbreakers should be used with ceramics.

199

Technical Information

MATERIAL SELECTION - MACHINING STAINLESS STEELS GUIDELINES TO SUCCESS USING CERMETS


Wear Resistance. The high hardness, low oxidation rate and exceptional lubricity of cermets result in greater wear resistance and lower frictional forces when cutting stainless steels. Surface Finish. Cermets resist cutting edge build-up and are much freer cutting than carbides. As a result, surface finishes on stainless steels are excellent. Chip Control. Stringy chips are a constant problem when machining stainless steels. By using NTK's variety of chipbreakers, this problem can be solved. Chipbreakers. Positive geometries and positive chipbreakers work best on stainless. Several NTK chipbreaker designs show best results - NI, FN, ZP, CM5, B&C. See chip control pages for specifications.

Speed & Feed Recommendations - Turning & Milling Stainless Steels


Stainless Steel Hardness 160 400 SeriesMartensitic and Ferritic 350 200 Type of Cut Roughing Semi-Finishing Roughing Semi-Finishing Roughing Semi-Finishing Milling 200 300 SeriesAustenitic 350 260 Roughing Semi-Finishing Roughing Semi-Finishing Roughing Semi-Finishing Roughing Semi-Finishing Milling Precipitation Hardness
Technical Information

NTK Grade C7X XT3 C7X XT3 XN4 XT3/T3N C7X C7X/XT3 C7X XT3/ C7X XN4 XT3/ C7X XN4 XT3/T3N C7X C7X XN4/ C7X XN4 XT3/T3N C7X C7X

S.F.M. Range 450 - 600 600 - 1000 400 - 550 500 - 850 200 - 500 250 - 700 450 - 750 500 - 800 250 - 600 300 - 800 250 - 575 300 - 700 175 - 450 250 - 600 350 - 600 450 - 700 300 - 700 250 - 500 250 - 600 300 - 550 400 - 600

Feed Range .008 - .014 .008 - .015 .006 - .013 .006 - .013 .004 - .012 .004 - .012 .003 - .005 .003 - .005 .006 - .012 .006 - .010 .003 - .011 .003 - .011 .003 - .010 .003 - .010 .003 - .006 .003 - .005 .008 - .014 .005 - .012 .004 - .012 .003 - .005 .003 - .004

Max. D.O.C. .150 .075 .125 .075 .075 .060 .150 .125 .125 .075 .100 .050 .070 .040 .150 .125 .090 .080 .075 .100 .075

Roughing Semi-Finishing 175 250 350 Semi-Finishing Semi-Finishing Semi-Finishing Roughing Semi-Finishing

(17-4 etc) Milling

200

EDGE PREPARATION OF CERAMICS


Much of the success of ceramics are the result of using the correct edge preparations. Since ceramic is such a hard material, it needs some edge work in order to withstand cutting forces to optimize the cutting tool performance. The correct edge preparation must correspond to the ceramic grade being used, the kind of material being machined and the machining operation being performed. The majority of ceramic applications can be handled with NTK's standard edge preparations. These edges are described on the next page. Whenever possible use a stocked standard edge preparation. As special conditions arise, then the edge preparation will have to be modified to meet these conditions. The following chart offers an explanation of edge preparations.

Explanation of Ceramic Cutting Edges


Up sharp edges are not recommended for ceramics. Only cermets in some special cutting tool applications.

EDGE STRENGTH INCREASES

Hones help protect the edge of ceramics from chipping or fracturing. Feed rates must be greater than the hone size to prevent a rubbing rather than a cutting action. Excessive honing reduces tool life.

Angle of T-Land

Width of T-Land

This geometry is typically the most common ceramic edge preparation. The cutting forces are distributed over a concentrated area of the ceramic edge. Aword of caution - the larger the T-land or hone the greater the cutting pressure, temperature and wear.

Angle of T-Land

Width of T-Land

A hone added to a T-land provides a stronger edge to prevent chipping. Usually this thype of geometry works best on interrupted cuts or turning hardened steels.
R(Hone)

Angle of T-Land

Width of T-Land

R(Hone)

Double T-lands and hones are generally used in heavy roughing cuts of hardened materials. This edge is extremely shock resistant but also generates large cutting forces.

201

Technical Information

EDGE PREPARATION FOR NTK CERAMICS Standard Edge Preparation for NTK Ceramics
Grade
HC1 HC2 HC6 HW2 ZC4 HC7 / ZC7 SE1 SX1 SX6 SX8 SP2 SX5 SX9 WA1 Negative Rake Positive Rake Negative Rake Positive Rake all sizes all sizes .002" T-land all sizes all sizes 5/16" or less 1/2" or over 5/16" or less 3/8" or over .004" T-land .008" T-land .004" T-land Positive Rake all sizes 5/16" or less 3/8" or over .002" T-land Negative Rake

Shape

Thickness
3/16" or less 1/4" or over

I.C. Size
all sizes

NTK Std. Edge Prep.


.004" T-land .008" T-land

Recommended Edge Preparation for HC1, HC2, HC6, HC7, HW2, ZC4, ZC7, SX1, SX5, SX6, SX8, SX9, SP2, WA1
Material
Cast iron

Application
Rough Fine Finish Rough

Shape & Edge Preparation


Negative rake .008" T-land (standard) Positive rake .002" T-land (standard) Negative rake .004" T-land (standard) Negative rake .008" T-land (standard) 7.94 thick Negative rake .016" T-land (standard) 7.94 thick with Hone Negative rake .004" T-land (standard) Negative rake .008" T-land (standard) Negative rake .008" T-land (standard) Negative rake .008" T-land (special) with Hone Negative rake .008" T-land (special) Negative rake .004" T-land (standard) Positive rake .002" T-land (standard) Positive rake .008" T-land with Hone (special) CDH or RCGX Double T-land (standard) insert Positive rake .002" T-land Positive rake Heavy hone (special) Positive rake .002" T-land

Mild Steel

Finish-Semi-Finish Finish with interruption Finish-Semi-Finish

Hardened Steel
Technical Information

Fine Finish Finish-Semi-Finish Mill Roll Turning Rough Finish

Chilled Iron Hi-Ni Alloy INCONEL 718 WASPALOY etc.

202

Technical Data Damage and Solution


Normal Wear (Flank wear [VB]) Notch wear [VC]

Solution
Reduce the cutting speed. Increase the feed rate. Increase nose-R size. Change the tool grade for better wear resistance.

Solution
Change the tool grade for better wear resistance. Decrease the approch angle or change insert shape. Increase the feed rate.

Crater wear [KT]

Chipping

Solution
Reduce the cutting speed. Change dry cutting to wet cutting. Change the tool grade for better wear resistance.

Solution
Increase the amount of cutting-edge honing. Reduce the rake angle. Change the tool grade for better notch resistance.

Fracture and breakage

Thermal shock crack

Solution
Review the cutting conditions (reduce d f ). Increase the amount of cutting-edge honing. Change the tool grade for better notching resistance.

Solution
Reduce the cutting speed and the feed rate. Change wet cutting to dry cutting. Change the tool grade for better thermal shock resistance.

Built-up edge

Plastic Deformation
Technical Information
203

Solution
Increase the cutting speed and the feed rate. Increase the rake angle. Use coolant.

Solution
Reduce the cutting speed and feed rate. Reduce the cutting depth. Change the tool grade for better heat resistance.

Technical Data

Edge code

Shape of the edge


80-deg rhombic insert.

Dimensions (mm) r X Y 0.028 0.055 0.083 0.110 0.165 0.040 0.079 0.119 0.159 0.238 0.211 0.422 0.633 0.844 1.265 0.4 0.007 0.8 0.015 1.2 0.022 1.6 0.029 2.4 0.044

Edge code

Shape of the edge


35-deg rhombic insert

Dimensions (mm) r X Y 0.537 1.073 1.610 2.146 3.218 0.164 0.329 0.493 0.658 0.986 0.033 0.066 0.099 0.132 0.132 0.4 0.537 0.8 1.073 1.2 1.61

1.6 2.146 2.4 3.218


Square insert (Type 12).

80-deg rhombic insert Type 31)

0.4 0.040 0.8 0.079 1.2 0.119 1.6 0.159 2.4 0.238

0.4 0.164 0.8 0.329 1.2 0.493 1.6 0.658 2.4 0.986

55-deg rhombic insert

0.4 0.463 0.8 0.925 1.2 1.389 1.6 1.851 2.4 2.776

35-deg rhombic insert

0.4 0.923 0.8 1.846 1.2 2.769 1.6 3.692 2.4 5.538

55-deg rhombic insert

0.4 0.211 0.8 0.422 1.2 0.633 1.6 0.844 2.4 1.265

Square insert (Type 17)

0.4 0.003 0.8 0.006 1.2 0.009 1.6 0.012 2.4 0.017

Note: The values of X and Y in this table are based on a rake angle of 0 degrees. Therefore, these values slightly differ from actual ones. (Type XX) denotes the type number of a standard C-shaped holder.

Determining the measurement of the Insert Nose


Method of calculating the position of the nose(mm) Values of d used to calculate m and
Inscribed circle code Calculation value(d) Shape Calculation expression 5 6 7 8 0 3.971 4.761 5.561 6.351 7.941 9.525 12.701 15.875 19.051 25.401 Y 1 2 3 4 6 Nose code Nominal value 0.2 0.4 0.8 1.2 1.6 2.4

(mm)
Calculation value() 0.2032 0.3969 0.7938 1.1906 1.5875 2.3812

Technical Information

Triangular

m=

3 d- 2

2 -

Square

2 m= ( -1)

d - 2

3 4 5

Rhombic m=

E -1E( d -) C sin 2 C 2
1

6 8

204

Insert Radius Compensation List Nose-R and Cutting Edge Positional Dimensions
Edge code Shape of the edge
Triangular insert (Type 21, 22)

Dimensions (mm) r X Y 0.012 0.024 0.036 0.048 0.072 0.024 0.048 0.072 0.096 0.143 0.099 0.198 0.297 0.397 0.595 0.007 0.015 0.022 0.029 0.044 0.283 0.567 0.850 1.134 1.701 0.4 0.283 0.8 0.567 1.2 0.850 1.6 1.134 2.4 1.701

Edge code

Shape of the edge


Square insert (Type 13)

Dimensions (mm) r X Y 0.043 0.084 0.168 0.252 0.503 0.003 0.006 0.009 0.012 0.017 0.039 0.079 0.118 0.157 0.236 0.065 0.131 0.196 0.261 0.392 0.089 0.178 0.268 0.357 0.535
Technical Information
205

0.4 0.145 0.8 0.291 1.2 0.436 1.6 0.581

A (G)

Square insert (Type 11, 16)

0.4 0.089 0.8 0.178 1.2 0.268 1.6 0.357 2.4 0.535

E (T)

2.4 0.872
Triangular insert (Type 24)

0.4 0.397 0.8 0.794 1.2 1.191 1.6 1.587 2.4 2.281

Triangular insert (Type 23)

0.4 0.370 0.8 0.740 1.2 1.110 1.6 1.480 2.4 2.219

Square insert

0.4 0.033 0.8 0.066 1.2 0.099 1.6 0.132 2.4 0.089

B (R)

80-deg rhombic insert (Type 21, 22)

0.4 0.028 0.8 0.055 1.2 0.083 1.6 0.110 2.4 0.165

55-deg rhombic insert

0.4 0.344 0.8 0.687 1.2 1.031 1.6 1.375 2.4 2.062

Triangular insert (Type 25)

0.4 0.012 0.8 0.024 1.2 0.036 1.6 0.048 2.4 0.072

J
35-deg rhombic insert

0.4 0.839 0.8 1.679 1.2 2.518 1.6 3.357 2.4 5.036

C (F)

Square insert (Type 14)

0.4 0.164 0.8 0.329 1.2 0.493 1.6 0.658 2.4 0.986

Square insert (Type 15)

0.4 0.024 0.8 0.048 1.2 0.072 1.6 0.096 2.4 0.143

Technical Data Screw and Wrench List for Holders


Shape Screw No. LR-S-23.7 LR-S-24.4 LR-S-25.5
Torx

Dimensions (mm) a M20.4 M20.4 M20.4 M2.50.45 M2.50.45 M2.50.45 M30.5 M30.5 M40.7 M40.7 M2.20.45 M2.50.45 M30.5 M30.5 M40.7 M40.7 M40.7 M50.8 M50.8 M61 M61 M81 b 3.2 3.2 3.2 3.6 3.6 3.6 5.2 4.2 5.8 5.8 3.2 3.6 4.0 4.4 5.8 5.8 5.8 7.0 6.4 8.0 8.0 11.0 c 3.7 4.4 5.5 4.8 6.0 6.8 6.2 7.8 5.8 9.0 6.0 7.0 6.0 9.0 6.0 8.0 10.0 10.0 13.5 13.5 10.5 13.5 Torx T6 T6 T6 T7 T7 T7 T10 T10 T10 T10 T6 T7 T10 T8 T15 T15 T15 T20 T10 T20 T20 T20

Wrench Item-No. RLR-13S RLR-13S RLR-13S RLR-15S RLR-15S RLR-15S RLR-20S RLR-20S RLR-20S RLR-20S RLR-13S RLR-15S RLR-20S

LR-S-2.54.8
90 b

LR-S-2.56 LR-S-2.56.8
c

LR-S-36.2 LR-S-37.8 LR-S-45.8 LR-S-49 LRIS-2.26 LRIS-2.57


Torx

LRIS-36
60 b

1230 - C LRIS-46
c

LLR-25S LLR-25S LLR-25S LLR-28S RLR-20S LLR-28S LLR-28S LLR-28S

LRIS-48 LRIS-410

ISO standard
Technical Information
Torx

LRIS-510 1150 - C 1160 - C 1161 - C 1180 - C

206

GRADE CROSS REFERENCE CHART


CERAMICS
SUMITOMO Taegue Tec / Ingersoll AW20 AB30 AB20 Ssang Yong (Cerabit) Carboloy / Seco VALENITE Greenleaf Indexable I50 I100 KYOCERA Newcomer SPK (Ceramtech) SANDVIK TOSHIBA KENNAMETAL ROMAY ISCAR IN11 IN23 IN22 Hertel AC5 NTK HC1 HW2 SE1 HC2 HC5 Q35 CC6050 ( VPZ205) (VPZ215) HC7 (ZC7) KY4400 HC6 WA1 KY4300 CC670 (ZC4)

KO60 CC620 KO90 CC650 KY1615 Q32

SN60 SN80 SH1 SH2

CC10 CC20 NB90S LX21 C30 (CC30C)

SN60 GEM-19 AZ5000 A65 GEM-7

440 460

NP5200 SZ200 ST100 ST300

MC2 NP5000

(LX11) (A66N) WG300

ST300 SD200

( ) : Coating

SILICON NITRIDE
KENNAMETAL GREENLEAF VALENITE KYOCERA Indexable Taegue Tec / Ingersoll SUMITOMO SANDVIK TOSHIBA Ssang Yong (Cerabit) ROMAY CC514 CC5143 CC52 CC52J
( ) : Coating

KY3500 Q6 NS260 SL800 SX1 SX6 ( CC6090 FX105 KS500 ( VPQ130 (NS260C) KY3400) SL550C) SP2 SX8 KY3000 GC1690 CC690 KY1540 KY2000 CC6060 KY2100 CC6065 SPM014 Q65 Q60 KS7000 KS6000 SL500 SL200 GSN

ISCAR IS8 HITACHI

SPK

NTK

SN400 AS10

MW43

IS8 AS10 (CC58) SN500 ( SC10) (IS80) (CC58J) SN26 IS8 MW30 CC513 AS10 SN300 SN700 MW47 CC5477

SX5 SX9

Q8

M101S

CERMET
KENNAMETAL VALENITE KYOCERA Taegue Tec / Ingersoll KORLOY SUMITOMO SANDVIK TOSHIBA MITSUBISHI ISCAR DIJET
( ) : Coating

NTK T3N XT3 C7X C7Z XN4

CT5015 VC605 ( T05A TN30 CN100 KT125 HT2 CT5005 NS520 ( IC20N NX1010) VC610 T110A PV30) CT10 CT515 CT525 KT150 ( GC1525) KT175 PS5 KT175 (NX2525) (T1200A) NS530 TC40 (ATM530) (PV60) NS530 TC50 VC671 ( AP25N) T2000Z ( ATM530) TN60 VC673

CH350 LN11

CN20

CH530 CX90 CH5050 CX99

TN60 NX99 T130A NS540 VC630 ( UP35N) ( ) (AT520) TN100M IC40T CN20 T1200A VC675 ( NX2525) TN6020

CARBIDE
KENNAMETAL VALENITE KYOCERA KORLOY SUMITOMO WALTER SANDVIK TOSHIBA MITSUBISHI HITACHI ISCAR SECO DIJET NTK

K45 K68 KM1 ( KC9025) (KC9215)

SMA VC6 ST20E TX10S UC6010 IC50M ST15 WS20B ( H13A VC27 ( U2 TU10 ( U20 STi10T) ( CA6015) IC08 JC215V) (GC4015) (SV310) AC900G) (T9015) (IC9015) (CN200) WAM10B (US7020) ( (GC2025) (VP1510) AC304) (T6020) (IC507) (IC9025) (NC310) (IC8040)

TTM AT10 (TP1000) (TP400) ( ) (TP200) WAP20 (WAM20) (TP1000) ( ) (TP100) WAP10 (T25M) (TP200) (WTL41) (TP25)
( ) : Coating

( )( ) ( )( ) (ZM3) KC9125 GC4025 (VP5525) UC6010 AC2000 (T7025) (UC6020) (AC3000) (KC8050) (GC2025) ( )( ) (VM1) KC9110 GC3005 (KC9315) (GC4005) ( ) ( ) GC1025 (QM3) KC792M (GC4025) (KC935) (GC2025) (VP5525) (UE6005) (VP5515) (UC6010) ( ) (SV901) GP20M ( ) (SV230) U65 (US735)

(AC1000) (AC700G) (ACZ330) (AH330) (IC635) (AC2000) (T7025) (PR630) (IC8025) (PC230) (CY150) (JC730V) (IC9025) (EH20Z) (GH330)

207

Technical Information

Technical Data
Conversions on Brinell Hardness of Steel
Brinell hardness Special brale indenter Brinell 10mm balls, 3000kgf load kgf/mm2 Scale B Vickers Shore hardrecess Scale A Load: 100 kgf Scale C Scale D [N/mm2] ness diameter Standard Hultgren Tungsten hardness Load: 60 kgf Diameter: Load: 150 kgf Load: 100 kgf 15-N scale 30-N scale 45-N scale Approximate brale brale brale Load: 15 kgf Load: 30 kgf Load: 45 kgf" ball ball carbide ball mm 1/16"" value (1) indenter
85.6 85.3 85.0 84.7 84.4 84.1 83.8 83.4 83.0 82.6 82.2 82.2 81.8 81.3 81.2 81.1 80.8 80.6 80.5 80.7 79.8 79.8 79.1 78.8 78.4 78.0 77.8 77.1 76.9 76.7 76.4 76.3 75.9 75.6 75.6 75.1 74.9 74.9 74.3 74.2 74.2 73.4 72.8 72.0 71.4 70.6 70.0 69.3 68.7 68.1 67.5 66.9 66.3 65.7 65.3 64.6 64.1 63.6 63.0 62.5 61.8 61.4 60.8 -

Rockwell hardness

Special Rockwell hardness

Tensile strength

indenter
(110.0) (109.0) (108.5) (108.0) (107.5) (107.0) (106.0) (105.5) (104.5) (104.0) (103.0) (102.0) (101.0) 100.0 99.0 98.2 97.3 96.4 95.5 94.6 93.8 92.8 91.9 90.7 90.0 89.0 87.8 86.8 86.0 85.0 82.9 80.8 78.7 76.4 74.0 72.0 69.8 67.6 65.7

indenter
68.0 67.5 67.0 66.4 65.9 65.3 64.7 64.0 63.3 62.5 61.8 61.7 61.0 60.1 60.0 59.7 59.2 58.8 58.7 59.1 57.3 57.3 56.0 55.6 54.7 54.0 53.5 52.5 52.1 51.6 51.1 51.0 50.3 49.6 49.6 48.8 48.5 48.5 47.2 47.1 47.1 45.7 44.5 43.1 41.8 40.4 39.1 37.9 36.6 35.5 34.3 33.1 32.1 30.9 29.9 28.8 27.6 26.6 25.4 24.2 22.8 21.7 20.5 (18.8) (17.5) (16.0) (15.2) (13.8) (12.7) (11.5) (10.0) (9.0) (8.0) (6.4) (5.4) (4.4) (3.3) (0.9) -

indenter
76.9 76.5 76.1 75.7 75.3 74.8 74.3 73.8 73.3 72.6 72.1 72.0 71.5 70.8 70.7 70.5 70.1 69.8 69.7 70.0 68.7 68.7 67.7 67.4 66.7 66.1 65.8 65.0 64.7 64.3 63.9 63.8 63.2 62.7 62.7 61.9 61.7 61.7 61.0 60.8 60.8 59.7 58.8 57.8 56.8 55.7 54.6 53.8 52.8 51.9 51.0 50.0 49.3 48.3 47.6 46.7 45.9 45.0 44.2 43.2 42.0 41.4 40.5 -

2.25 2.30 2.35 2.40 2.45 2.50

495 477 461 444 429 415 401 388 375 363 352 341 331 321 311 302 293 285 277 269 262 255 248 241 235 229 223 217 212 207 201 197 192 187 183 179 174 170 167 163 156 149 143 137 131 126 121 116 111

601 578 555 534 514 495 477 461 444 429 415 401 388 375 363 352 341 331 321 311 302 293 285 277 269 262 255 248 241 235 229 223 217 212 207 201 197 192 187 183 179 174 170 167 163 156 149 143 137 131 126 121 116 111

767 757 745 733 722 712 710 698 684 682 670 656 653 674 638 630 627 601 578 555 534 514 495 477 461 444 429 415 401 388 375 363 352 341 331 321 311 302 293 285 277 269 262 255 248 241 235 229 223 217 212 207 201 197 192 187 183 179 174 170 167 163 156 149 143 137 131 126 121 116 111

940 920 900 880 860 840 820 800 780 760 740 737 720 700 697 690 680 670 667 677 640 640 615 607 591 579 569 553 547 539 530 528 516 508 508 495 491 491 474 472 472 455 440 425 410 396 383 372 360 350 339 328 319 309 301 292 284 276 269 261 253 247 241 234 228 222 218 212 207 202 196 192 188 182 178 175 171 163 156 150 143 137 132 127 122 117

93.2 93.0 92.9 92.7 92.5 92.3 92.1 91.8 91.5 91.2 91.0 91.0 90.7 90.3 90.2 90.1 89.8 89.7 89.6 89.8 89.0 89.0 88.4 88.1 87.8 87.5 87.2 86.7 86.5 86.3 86.0 85.9 85.6 85.3 85.3 84.9 84.7 84.7 84.1 84.0 84.0 83.4 82.8 82.0 81.4 80.6 80.0 79.3 78.6 78.0 77.3 76.7 76.1 75.5 75.0 74.4 73.7 73.1 72.5 71.7 70.9 70.3 69.7 -

84.4 84.0 83.6 83.1 82.7 82.2 81.7 81.1 80.4 79.7 79.1 79.0 78.4 77.6 77.5 77.2 76.8 76.4 76.3 76.8 75.1 75.1 73.9 73.5 72.7 72.0 71.6 70.7 70.3 69.9 69.5 69.4 68.7 68.2 68.2 67.4 67.2 67.2 66.0 66.8 65.8 64.6 63.5 62.3 61.1 59.9 58.7 57.6 56.4 55.4 54.3 53.3 52.2 51.2 50.3 49.3 48.3 47.3 46.2 45.1 43.9 42.9 41.9 -

75.4 74.8 74.2 73.6 73.1 72.2 71.8 71.0 70.2 69.4 68.6 68.5 67.7 66.7 66.5 66.2 65.7 65.3 65.1 65.7 63.5 63.5 62.1 61.6 60.6 59.8 59.2 58.0 57.6 56.9 56.2 56.1 55.2 54.5 54.5 53.5 53.2 53.2 51.7 51.5 51.5 49.9 48.4 46.9 45.3 43.6 42.0 40.5 39.1 37.8 36.4 34.4 33.8 32.4 31.2 29.9 28.5 27.3 26.0 24.5 22.8 21.5 20.1 -

97 96 95 93 92 91 90 88 87 86 84 83 81 80 79 77 75 73 71 70 68 66 65 63 61 59 58 56 54 52 51 50 48 47 46 45 43 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 23 22 21 20 19 18 15

210 {2095} 205 {2010} 202 {1981} 195 {1912} 193 {1893} 189 {1854} 186 {1824} 186 {1824} 181 {1775} 177 {1736} 177 {1736} 172 {1687} 170 {1667} 170 {1667} 162 {1589} 162 {1589} 162 {1589} 154 149 142 136 129 124 120 115 112 108 105 103 99 97 94 91 89 86 84 82 {1510} {1461} {1392} {1334} {1265} {1216} {1177} {1128} {1098} {1059} {1030} {1010} {971} {951} {922} {892} {873} {843} {824} {804}

2.55

2.60

2.65

2.70

2.75

2.80

2.85

2.90

2.95 3.00 3.05 3.10 3.15 3.20 3.25 3.30 3.35 3.40 3.45 3.50 3.55 3.60 3.65 3.70 3.75 3.80 3.85 3.90 3.95 4.00 4.05 4.10 4.15 4.20 4.25 4.30 4.35 4.40 4.45 4.50 4.55 4.60 4.65 4.70 4.80 4.90 5.00 5.10 5.20 5.30 5.40 5.50 5.60

80 {785} 78 {765} 74 {726} 72 {706} 70 69 67 65 63 63 61 60 58 57 56 53 51 50 47 46 44 42 41 39 {686} {677} {657} {637} {618} {618} {598} {588} {569} {559} {549} {520} {500} {490} {461} {451} {431} {412} {402} {382}

Technical Information

Notes: 1. The numerals parenthesized in this table are usually not used. 2. The units and values enclosed in braces ({ }) in this table are based on SI units and are shown for reference only. (1 N/mm2 = 1 MPa) 3. This table is an excerpt from the JIS Iron and Steel Handbook.

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For safe use of the Extra Hard Tool Product safety.


1. To use extra hard tool product.
In accordance with the Product Liability Law (PL law) that has been in effect since July 1, 1995, we affix warning labels or caution labels to the packages of the products which are covered by the law. However, we donf t affix specific caution labels onto the tool itself. Therefore, please read this leaflet before using extra hard tool products and extra hard tool materials. In addition, we would like to ask you to inform your operators of the content of this leaflet as part of your safety training.

2. Basic features of extra hard tool materials


2-1. Meaning and usage of terms in this leaflet
Extra hard tool material: Generic name for tool materials such as extra hard alloys, cermet, ceramic, CBN sintering material and diamond sintering material. Extra hard alloy : Tool material which is mainly made of WC (Carbonized tungsten) Extra hard : Abbreviation for extra hard tool materials, or the abbreviation for extra hard alloy in the narrow sense. Extra hard tool : Generic name of tools which are made of extra hard tool material.

2-2. Physical characteristics


Appearance: Each material is different. Example: Gray, black, gold color, etc. Odor: None Hardness : Extra hard cermet: HV500 to 3000kg/mm2, Ceramic : HV1000 to 4000kg/mm2 Hardness : CBN sintering material : HV 2000 to 5000 kg/mm2, Diamond sintering material: HV8000 to 12000kg/mm2 Gravity: Extra hard: 9 to 16, cermet: 5 to 9, cerami : 2 to 7, CBN and diamond sintering material 3 to 5

2-3. Component
Carbide, nitride, carbonitride, oxide such as W, Ti, Al, Si, Ta, B, and materials that contain Co, Ni, Cr, Mo, etc. in addition to those compounds.

3. Cautions for handling extra hard tool materials


Extra hard materials can sometimes be quite fragile, although they are normally very hard. The materials may be damaged by sharp impact or excessive tightening. Since extra hard materials have high specific gravity, care should be taken when handling large products or large amounts of the products which are made of those materials. Extra hard materials have different thermal expansion ratios from other metallic materials. Therefore, cracks may occur in the product after shrinkage fit or cold shrinkage fit because the temperature for use is significantly higher or lower than the specification temperature. If the extra hard material has corrosion due to liquid for grinding, lubricant or water, etc., the strength of the material will be deteriorated significantly. Be sure to store the material where it will not come in contact with liquids or water.

4. Cautions for machining extra hard tools


Extra hard tools may lose strength significantly depending on the surface condition. Be sure to use diamonds for grinding. Extra hard tools may generate dust during grinding. If you inhale a great deal of the dust, it may affect your health. Please make sure to have equipment for disposal and wear protective devices such as a mask, etc. If the dust comes in contact with your bare skin gets into your eyes, wash thoroughly with water. When grinding the extra hard material or soldered material, heavy metal component will be included in the waste fluid. So, make sure to dispose of the waste fluid properly. When regrinding extra hard tools, do a post check to be sure that no cracks have occurred. ings at places where stress will be applied. If electric discharge machining is conducted on the extra hard material, remnant cracks may occur on the surface which cause the material to weaken. Be sure to remove any cracks by grinding, if necessary. When soldering the extra hard materials, if the material temperature is much lower or higher than the melting temperature of the soldering material, it may cause defluxion or breakage of the product. Be careful about the temperature.

209

Technical Information

If you use a laser or electric pen, etc. to mark the extra hard material or products, it may cause cracks. Do not make mark-

Technical Data Cautions for using cutting tools


Objective product
Cutting tools in general

Danger
This type of tool has very sharp blade. If you touch it directly, you may get injured. If you use it improperly or if the conditions for use are inappropriate, it may cause breakage or shattering of the tool, which may result in injury. Sudden increase of cutting resistance due to a mixture of impact and burden or excessive abrasion may cause breakage or shattering of the tool, which may result in injury. Tools or workpieces will be very hot while cutting. Therefore, if you touch them immediately after the machining, you may get burn injury. Sparks, heat generated due to breakage while cutting, cutting chips may also cause a fire.

Countermeasure
Wear protective gear, such as protective gloves, etc., especially when taking out the product from the case or attaching the tool to a machine, Wear protective gear such as safety covers or protective glasses. l use within the recommended purpose of usage. Refer to the operation manual, catalogue, etc. Wear protective gear such as safety cover or protective glasses. Stop the machine, wear the protective gloves and use tools such as nipper or clipper, etc. to remove cutting chips. Wear protective gear such as protective gloves.

Do not use the tool where there is a possibility of fire or explosion. If you use insoluble cutting lubricant, be sure to have antifire provisions. Wear protective gear such as safety cover or protective glasses. Make sure to have a trial operation in advance in order to confirm that there is no vibration or abnormal sound. Do not touch with bare hands. Clean the surface for attachment of an insert or the part for fixture of the insert completely before attaching the insert. Make sure that the insert or the part is clamped securely using a spanner provided with the product before attachment. Also, do not use any inserts or parts other than the ones provided with the products. Do not use a tool such as a pipe. Use the spanner which is provided with the product. Use the tools only for the recommended purposes. Refer to the operation manual, catalog, or other source of information. Wear protective gear such as protective gloves, etc.

When using the tool at high speed rotation if the whole machine including the holder of the machine is not well balanced, the tool may get broken due to tremor or vibration, which may result in injury. Touching burrs on the machined product directly may result in injury. Throw-away type (blade change type) tools in general If the chip or parts are not clamped securely, those may fall down or scatter while cutting, which may cause injury.

If the tool is tightened too tightly using a tool such as pipe, etc., the chip or tool may fall down or shatter while cutting. This is dangerous. When using the tool at high speed rotation, a part or chip may be thrown out by centrifugal force, which is very dangerous. Be careful about handling the tool safely. Cutters and other tools that are rotated for use The sharp cutter blades may cause injury if you touch them directly with your hands. The tool may be deflected due to eccentric rotation or bad balance that will cause vibration, breakage or scattering of the tool, which may result in injury.

Use the tool within the recommended rotation speed. Check and adjust the accuracy of rotating section or balance periodically so that eccentric rotation or deflection does not occur due to abrasion of the bearings, etc. Confirm that the soldering is secure before use. Do not use under conditions which may cause the tool to reach high temperatures. Do not use the chip which has been soldered many times because the strength will be lower. Use the tools only as specified.

Soldering tool

You may get injured due to defluxion or breakage of the chips, etc. Repeating soldering many times may cause the chip to be broken easily. This is dangerous. Using the tool for other than its intended purposes may cause breakage of the machine or tool. This is very dangerous.

Others

Technical Information
210

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