Metallurgy and Machinability Metallurgy Overview

Machinability Overview

Cast irons are iron-carbon-silicon alloys containing large amounts of carbon either as graphite or as iron carbide. They have higher carbon (>1.7%) and silicon (1.0-3.5%) contents than steel. Silicon promotes dissociation of iron carbide to iron and graphite. By increasing the silicon content in cast iron, a greater proportion of graphite can be obtained at the expense of combined carbon. The microstructure and mechanical properties of cast irons can be controlled not only by chemical composition but also by cooling rate. Increasing the cooling rate will refine the graphite size as well as the matrix structure and will increase strength and hardness. It also may increase the chilling tendency, which may increase the hardness but decrease the strength.

Machinability refers to the ease with which a workpiece can be machined and measured in terms of tool life, metal removal rates, surface finish, ease of chip formation, or cutting forces. It is not an intrinsic property of a material, but is a result of complex interactions between the mechanical properties of the workpiece, cutting tools, lubricants used, and machining conditions.

Alloys within the broad group of cast irons include white iron, gray cast iron, mottled cast iron, malleable cast iron, and ductile cast iron. Each of these alloys may be modified by alloy additions to obtain specific properties. Below are selected ASTM standards for different classes of cast irons.

Selected ASTM Standards for Cast Irons Unalloyed Cast Irons A47 A48 A126 A159 A197 A220 A278 A319 A395 A476 A536 A602

Malleable iron castings Gray iron castings Gray iron castings for valves, flanges, and pipe fittings Automotive gray iron castings Cupola malleable iron Pearlitic malleable iron castings Gray iron castings for pressure-containment with temperatures up to 345° C (650° F) Gray iron castings for elevated temperatures – non-pressure containing parts Ferritic ductile iron pressure-retaining castings for elevated temperatures Ductile iron castings for papermill dryer rolls Ductile iron castings Automotive malleable iron castings

Low and Moderate Alloyed Cast Irons A319 A874

Gray iron castins for elevated temperatures for non-pressure – containing parts Ferritic ductile iron castings for low-temperature service parts

Cast iron machinability varies greatly depending on the type of iron and its microstructure. Ferritic cast irons are easiest to machine, while white irons are extremely difficult to machine. Other grades of cast iron, such as malleable, ductile, compacted graphite, and alloyed cast irons, are in between ferritic and white irons in ease of machinability. Additionally, hard spots in castings formed during rapid cooling and in presence of excessive levels of carbide forming elements can seriously degrade machinability. Alloy cast irons (ASTM A532, A518) can be classified as white cast irons, corrosion-resistant irons, and heat-resistant irons. Generally, they are based on the iron (Fe) - carbon (C) - silicon (Si) system and contain one or more alloying elements that are added (>3%) to enhance one or more useful properties (corrosion resistance or strength or oxidation resistance at elevated temperatures). Small amounts of ferrosilicon, cerium, or magnesium that are added to control the size, shape, and distribution of graphite particles are called inoculants, rather than alloying elements. Inoculation does not change the basic composition or alter the properties of the constituents in the microstructure. The alloyed irons for corrosion resistance are either 13-36% nickel (Ni) gray and ductile irons (also called Ni-resist irons) or high silicon (~14.5% Si) gray irons. For elevated temperature service, nickel (Ni), silicon (Si), or aluminum (Al) alloyed gray and ductile irons are employed.

High-Silicon Cast Irons A532

Abrasion-resistant cast irons

High-Nickel Austenitic Cast Irons A436 A439 571

32

Austenitic gray iron castings Austenitic ductile iron castings Austenitic ductile iron castings for pressurecontaining parts for low-temperature service Figure 1: Microstructure of white cast iron

Metallurgy and Machinability White cast irons, also known as abrasion-resistant cast irons, are an iron-carbon alloy in which the carbon content exceeds 1.7%. White cast iron does not have any graphite in the microstructure. Instead, the carbon is present either as ironcarbide or complex iron-chromium carbides (Figure 1), which are responsible for high hardness and resistance to abrasive wear. White iron shows a white, crystalline fracture surface because fracture occurs along the carbide plates. White iron can be produced either throughout the section or only on the surface by casting the molten metal against graphite or metal chill. In the latter case, it is referred to as chilled iron. Corrosion-resistant cast irons obtain their resistance to chemical wear primarily from their high alloy content of silicon, chromium, or nickel. Depending on which of the three alloys dominates the compositions, the corrosion-resistant material can be ferritic, pearlitic, martensitic, or austenitic.

minimum tensile strength to class 60 with 60 ksi minimum tensile strength). The fluidity of liquid gray iron and its expansion during solidification due to the formation of graphite are responsible for the economic production of shrinkage-free, intricate castings such as engine blocks. Most gray iron components are used in the as-cast condition. However, for specific casting requirements, they can be heat treated (annealed, stress relieved, or normalized). Other heat treatments include hardening and tempering, austempering, martempering, and flame or induction hardening.

Figure 2a: Type C flake graphite in gray iron

Figure 2b: Pearlite-ferrite gray cast iron

Figure 2c: Coarse pearlite in gray cast iron

Figure 2d: Pearlitic gray cast iron

Machinability – Alloy Cast Irons White irons and corrosion-resistant high-silicon (14.5%Si) gray irons are the most difficult cast irons to machine. Alloyed white irons such as nickel-hard (Ni-hard) alloys and high-silicon irons (ASTM A518) are generally ground to size or turned with a polycrystalline cubic boron nitride (PCBN) tool material such as Kennametal grades KB9640, KD120, or KB5625 Gray cast irons (ASTM A48, A126, A159, ASME AS278 and SAE J431) are named such because their fracture has a gray appearance and consists of graphite flakes embedded in a matrix of ferrite or pearlite, or a mixture of the two depending on the composition and cooling rate (Figures 2a-2d). Ferrite is a soft, low-carbon alpha iron phase with low tensile strength but high ductility. Pearlite consists of lamellar plates of soft ferrite and hard cementite. Gray irons contain 2.5 to 4% carbon (C), 1-3% silicon (Si), and manganese (Mn) (~0.1% Mn in ferritic gray irons and as high as 1.2% Mn in pearlitic gray irons). Sulfur (S) and phosphorus (P) may be present as residual impurities. Manganese is deliberately added to neutralize the sulfur. The resulting manganese sulfide is uniformly distributed in the matrix of gray iron as inclusions. ASTM specification A48 classifies gray cast irons in terms of tensile strength (class 20 with 20 ksi

Machinability – Gray Cast Irons Most gray cast irons are easier to machine than other cast irons of similar hardness and virtually all steels. This is because the graphite flakes in the microstructure act as chip breakers and serve as a lubricant for the cutting tool. Machining difficulties can still occur in gray iron if chills are present in corners and thin sections or when sand is embedded in the casting surface. The material also shows a tendency to break out during exit from the cut. Although the graphite in cast iron imparts its free-machining characteristics, the matrix surrounding the graphite determines tool life. In fully annealed state, cast irons have a ferritic matrix and exhibit the best machinability. (While not as soft as ferrite in steel, the ferritic cast iron shows better machinability than ferritic steel due to the slight hardening effect of the dissolved silicon and the chip breaking and lubricating effect of the graphite.) As the ferrite content decreases

Photomicrographs courtesy of Buehler Ltd., Lake Bluff, Illinois, USA, www.buehler.com

33

Metallurgy and Machinability and pearlite increases, tool life decreases rapidly. Both iron and alloy carbides, when present as large particles, are detrimental to tool life. Irons with higher phosphorous contents (~0.4%) form a hard constituent called steadite, which has a detrimental effect on tool life.

iron before casting. The nodules act as crack arresters and impart ductility to the material. By contrast, neither white iron nor gray iron shows a significant amount of ductility. Ductile iron is of higher purity (low phosphorus [P] and sulfur [S]) and is stronger than gray iron.

Gray cast irons are productively turned and milled with multi-layered alumina and TiCN coated inserts. The substrate tool material can be either carbide or silicon nitride-based ceramic. Cermet grades such as KT315 are ideal for light depth-ofcut applications. A pure silicon nitride grade such as KY3500 often yields the highest productivity on general turning and milling applications at high speeds. Drilling applications are highly dependent on the drill geometry as well as drill grade. Kennametal solid carbide drills in the TF (triple flute) and SE (sculptured edge) geometries in TiALN-coated grades KC7210 and KC7215 are the most desirable. For indexable insert drilling applications, TiALN-coated KC7725 and alumina coated KC7935 grades are the first choice for high-speed, high productivity applications.

With a high percentage of graphite nodules present in the microstructure, the matrix determines the mechanical properties of ductile iron. Table B compares the composition of ductile iron with that of gray iron and malleable iron.

Ductile (nodular) irons (ASTM A395, A476, A439, A536 and SAE J434), previously known as nodular iron or spheroidal-graphite cast iron, contain nodules of graphite embedded in a matrix of ferrite or pearlite or both (Figures 3a-3c). The graphite separates as nodules from molten iron during solidification because of additives cerium (Ce) and magnesium (Mg) introduced in the molten

Figure 3a: Ferritic annealed ductile iron

The ASTM classifies different grades of ductile irons in terms of tensile strength in ksi, yield strength in ksi, and elongation in percent. For example, ASTM A536 specifies five standard ductile iron grades: 60-40-18 / 65-45-12 (ferritic ductile iron), 80-55-06 (ferritic-pearlitic ductile iron), 100-70-03 (pearlitic ductile iron), and 120-90-02 (quenched and tempered martensitic ductile iron). Ferritic ductile iron — the ferrite matrix provides good ductility and impact resistance and tensile strength equivalent to low-carbon steel. Ferritic ductile iron can be produced “as-cast” or may be given an annealing treatment to obtain maximum ductility and low-temperature toughness. Ferritic-pearlitic ductile irons — usually produced in the “as cast” condition and feature both ferrite and pearlite in the microstructure. Properties are intermediate between ferritic and pearlitic ductile irons.

Figure 3b: Pearlite/ferrite ductile iron

Figure 3c: Coarse lamellar pearlite in ductile iron

Table B – Typical composition ranges for unalloyed cast irons composition % material gray iron malleable iron ductile iron

34

total carbon

silicon (Si)

chromium (Cr)

nickel (Ni)

manganese

molybdenum (Mo)

copper (Cu)

phosphorus (P)

sulfur (S)

cerium (Ce)

magnesium (Mg)

3.25-3.50

0.50-0.90

1.80-2.30

0.05-0.45

0.05-0.20

0.05-0.10

0.15-0.40

0.12 max

0.15 max

...

...

2.45-2.55

0.35-0.55

1.40-1.50

0.04-0.07

0.05-0.30

0.03-0.10

0.03-0.40

0.03 max

0.05-0.07

...

...

3.60-3.80

0.15-1.00

1.80-2.80

0.03-0.07

0.05-0.20

0.01-0.10

0.15-1.00

0.03 max

0.002 max

0.005-0.20

0.03-0.06

Metallurgy and Machinability Pearlitic ductile irons - the pearlitic matrix provides high strength, good wear resistance, and moderate ductility and impact resistance. While the aforementioned three types of ductile iron are most common and used in as-cast condition, ductile irons also can be alloyed and/or heattreated to provide additional grades as follows: Martensitic ductile irons are produced using sufficient alloy additions to prevent pearlite formation, and a quench-and-temper heat treatment to produce a tempered martensitic matrix. These materials have a high strength and wear resistance but lower levels of ductility and toughness. Bainitic ductile irons are produced through alloying and/or by heat treatment to provide a hard, wear-resistant material. Austenitic ductile irons are produced through alloying additions to provide good corrosion and oxidation resistance, magnetic properties, and strength and dimensional stability at high temperatures. Machinability - Ductile Irons The spherical graphite in ductile iron acts similar to the flake graphite in gray iron in chip breaking and lubrication in machining. Machinability increases with silicon content up to 3%, but decreases significantly at higher silicon levels. As in the case of gray cast iron, machinability decreases with increasing pearlite content in the microstructure. Finer pearlite structures also decrease machinability. Still, pearlitic ductile irons are considered to have the best combination of machinability and wear resistance. Cast irons with tempered martensitic structure have a better machinability than pearlite with similar hardness. Other microstructures such as acicular bainite and acicular ferrite formed during heat treatment of ductile irons have machinability similar to martensite tempered to the same hardness. The higher tensile strength of ductile irons compared to gray cast iron requires better rigidity within the machining system. Tool performance life may be slightly lower if run at gray cast iron surface speeds. Ductile cast irons can be productively turned and milled with multi-layered alumina and TiCN or PVD TiALN-coated inserts but at slightly slower speeds than gray cast irons. Malleable cast irons (ASTM A602 and A47) consist of uniformly dispersed and irregularly

shaped graphite nodules (often called “temper graphite” because it is formed by the dissolution of cementite in the solid state) embedded in a matrix of ferrite, pearlite (Figure 4), or tempered martensite. Malleable iron is cast as white iron and then heat-treated to impart ductility to an otherwise brittle material. Malleable iron possesses considerable ductility and toughness due to the nodular graphite and a lower carbon metallic matrix. It has good fatigue strength and damping capacity, good corrosion resistance, good magnetic permeability, and low magnetic retention for magnetic clutches and brakes. Malleable iron, like medium-carbon steel, can be heat treated to obtain different matrix microstructures (ferrite, pearlite, tempered pearlite, bainite, tempered martensite, or a combination of these) and mechanical properties. Malleable and gray irons differ in two respects: the iron carbide is partially or completely dissociated in malleable cast iron; the dissociation occurs only when the alloy is solid. However, the dissociation in gray cast iron occurs during the early stages of solidification; hence the difference in the character of graphite in each material.

Figure 4: Coarse pearlite in annealed malleable iron

Machinability – Malleable Cast Irons The machinability of malleable iron is considered to be better than that of free-cutting steel. Use lowstrength ductile iron machining recommendations. Austempered ductile irons (ADI) (ASTM A897-90) are used as cast, but some castings are heat treated to achieve desired properties. Austempered ductile irons are produced from conventional ductile iron through a special two-stage heat

Photomicrographs courtesy of Buehler Ltd., Lake Bluff, Illinois, USA, www.buehler.com

35

Metallurgy and Machinability treatment. The microstructure consists of spheroidal graphite in a matrix of acicular ferrite and stabilized austenite (called ausferrite) (Figure 5). The fine-grained acicular ferrite provides an exceptional combination of high tensile strength with good ductility and toughness. ADI can be given a range of properties through control of austempering conditions. Compared to conventional grades of ductile iron, ADI offers twice the tensile strength for a given level of elongation.

Compacted graphite iron (CGI) (ASTM A842) has a microstructure in which the graphite is interconnected like the flake graphite in gray cast iron, but the graphite in CGI is coarser and more rounded (Figure 6). In other words, the structure of CGI is between that of gray and ductile iron. The graphite morphology allows better use of the matrix, yielding higher strength and ductility than gray irons. The interconnected graphite in CGI provides better thermal conductivity and damping capacity than the spheroidal graphite in ductile iron. Although the CGI is less section-sensitive than gray iron, high cooling rates are avoided because of the high propensity of the CGI for chilling and high nodule count in thin sections.

Figure 5: Austempered ductile iron

Machinability – Austempered Ductile Irons The machinability of the softer grades of austempered ductile iron (ADI) is equal or superior to that of steels with equivalent strength. ADI can be machined complete in the soft, as-cast state before heat treatment. This enables faster machine feeds and speeds and significantly increases tool life. As the hardness of ADI increases, tool life decreases substantially. For this reason, only the 125/80/10 and 150/100/7 grades of ADI are machined after austempering. Processing sequence for parts processed to the higher strength: • cast the component

Figure 6: Compacted graphite

Machinability – Compacted Graphite Iron The graphite morphology in compacted graphite iron enables chipbreaking but is strong enough to prevent powdery chip formations. This combination is ideal for good machinability. As a result, the machinability of compacted graphite iron lies between that of gray iron and ductile iron for a given matrix structure. Use low-strength ductile iron machining recommendations.

• subcritically anneal to a fully ferritic matrix • machine • austemper • finish machine (if required) • finish operations (rolling, grinding, peening, if required) Follow high-strength ductile iron recommendations during machining. 36

Photomicrographs courtesy of Buehler Ltd., Lake Bluff, Illinois, USA, www.buehler.com

Metallurgy and Machinability Gray Cast Irons & Gray, Austenitic standard materials

Gray Cast Irons

Gray, Austenitic

UNS

tensile strength

hardness HB

ASTM 48

ASTM A126

ASTM A159 & SAE J431

ASTM A278 & ASME AS278

ASTM A319

ASTM A436

F10001

generally below MPa 207 (30 ksi)

—

Class l

F10002

at or above 207 MPa (30 ksi)

—

Class ll

F10003

generally at or above 276 MPa (40 ksi)

—

F10004

124 MPa (18 ksi) min.

187 max

G1800

F10005

173 MPa (25 ksi) min.

170-229

G2500

F10006

207 MPa (30 ksi) min.

187-241

G3000

F10007

241 MPa (35 ksi) min.

207-255

G3500

F10008

276 MPa (40 ksi) min.

217-269

F11401

138 MPa (20 ksi) min.

156

F11501

145 MPa (21 ksi) min.

156

F11701

172 MPa (25 ksi) min.

174

25 (A-C)

F12101

207 MPa (30 ksi) min.

210

30 (A-C)

F12102

214 MPa (31 ksi) min.

210

F12401

241 MPa (35 ksi) min.

212

35 (A-C)

F12801

276 MPa (40 ksi) min.

235

40 (A-C)

F12802

283 MPa (41 ksi) min.

235

F12803

276 MPa (40 ksi) min.

235

F13101

310 MPa (45 ksi) min.

250

F13102

310 MPa (45 ksi) min.

250

F13501

345 MPa (50 ksi) min.

265

F13502

345 MPa (50 ksi) min.

265

F13801

379 MPa (55 ksi) min.

282

F13802

379 MPa (55 ksi) min.

282

F14101

414 MPa (60 ksi) min.

302

F14102

414 MPa (60 ksi) min.

302

60

F14801

483 MPa (70 ksi) min.

—

70

F15501

552 MPa (80 ksi) min.

—

80

F41000

172 MPa (25 ksi) min.

131-183

1

F41001

207 MPa (30 ksi) min.

149-212

1b

F41002

172 MPa (25 ksi) min.

118-174

2

F41003

207 MPa (30 ksi) min.

171-248

2b

F41004

172 MPa (25 ksi) min.

118-159

3

F41005

172 MPa (25 ksi) min.

149-212

4

F41006

138 MPa (20 ksi) min.

99-124

5

F41007

172 MPa (25 ksi) min.

124-174

6

Class lll

G4000 20 (A-C)

20 Class A 25 30 Class B 35

Class C 40 45 (A-C) 45 50 (A-C) 50 55 (A-C) 55 60 (A-C)

Grade, Type or Number

37

Metallurgy and Machinability Malleable Cast Irons & Pearlitic, Martensitic standard materials

Malleable Cast Irons

UNS

tensile strength

yield strength

hardness HB

ASTM A47

ASTM A220

F20000

345 MPa (50 ksi) min.

220.5 MPa (32 ksi) min.

156 max.

M3210

F20001

447.9 MPa (65 ksi) min.

309.7 MPa (45 ksi) min.

163-217

M4504

F20002

516.5 MPa (75 ksi) min.

345 MPa (50 ksi) min.

187-241

M5003

F20003

516.5 MPa (75 ksi) min.

379.3 MPa (55 ksi) min.

187-241

M5503

F20004

620.3 MPa (90 ksi) min.

482.2 MPa (70 ksi) min.

229-269

M7002

F20005

723.2 MPa (105 ksi) min.

586 MPa (85 ksi) min.

269-302

M8501

F22200

345 MPa (50 ksi) min.

224 MPa (32 ksi) min.

156 max.

32510

F22400

365 MPa (53 ksi) min.

241 MPa (35 ksi) min.

156 max

35018

Malleable,

F22830

414 MPa (60 ksi) min.

276 MPa (40 ksi) min.

149-197

40010

Pearlitic &

F23130

448 MPa (65 ksi) min.

310 MPa (45 ksi) min.

156-197

45008

Martensitic

ASTM A602 & SAE J158

F23131

448 MPa (65 ksi) min.

310 MPa (45 ksi) min.; elongation 6% min.

156-207

45006

F23530

483 MPa (70 ksi) min.

345 MPa (50 ksi) min.

179-229

50005

F24130

483 MPa (70 ksi) min.

345 MPa (50 ksi) min.

196-241

60004

F24830

586 MPa (80 ksi) min.

483 MPa (70 ksi) min.

217-269

70003

F25530

655 MPa (95 ksi) min.

552 MPa (80 ksi) min.

241-285

80002

F26230

724 MPa (105 ksi) min.

621 MPa (90 ksi) min.

269-321

90001

Grade, Type, or Number

Ductile Cast Iron & Ductile, Austenitic standard materials

Ductile Cast Iron

Ductile, Austenitic

38

UNS

tensile strength

yield strength

hardness HB

ASTM A395 A476 A536

ASTM A439

ASTM A571

AMS

as req’d

SAE J434

F30000

as required

F32800

414 MPa (60 ksi) min.

276 MPa (40 ksi) min.

170 max. 60-40-18

D4018

F33100

448 MPa (65 ksi) min.

310 MPa (45 ksi) min.

156-217

D4512

F33101

414 MPa (60 ksi) min.

310 MPa (45 ksi) min.

190

F33800

552 MPa (80 ksi) min.

379 MPa (55 ksi) min.

187-255

80-55-06

163

80-60-03

MIL-I24137

DQ & T

65-45-12 5315

(A) D5506

F34100

552 MPa (80 ksi) min.

414 MPa (60 ksi) min.

F34800

689 MPa (100 ksi) min.

483 MPa (70 ksi) min.

241-302 100-70-03

5316

F36200

827 MPa (120 ksi) min.

621 MPa (90 ksi) min.

270-350 120-90-02

F43000

400 MPa (58 ksi) min.

207 MPa (30 ksi) min.

139-202

D-2

F43001

400 MPa (58 ksi) min.

207 MPa (30 ksi) min.

148-211

D-2B

F43002

400 MPa (58 ksi) min.

193 MPa (28 ksi) min.

121-171

D-2C

F43003

379 MPa (55 ksi) min.

207 MPa (30 ksi) min.

139-202

D-3

F43004

379 MPa (55 ksi) min.

207 MPa (30 ksi) min.

131-193

D-3A

F43005

414 MPa (60 ksi) min.

207 MPa (30 ksi) min.

202-273

D-4

F43006

379 MPa (55 ksi) min.

207 MPa (30 ksi) min.

131-185

D-5

F43007

379 MPa (55 ksi) min.

207 MPa (30 ksi) min.

139-193

D-5B

F43010

448 MPa (65 ksi) min.

207 MPa (30 ksi) min.

121-171

F43020

379 MPa (50 ksi) min.

207 MPa (30 ksi) min.

—

(B)

F43021

345 MPa (50 ksi) min.

172 MPa (25 ksi) min.

—

(C)

D7003

D-2M-1, D-2M-2

Grade, Type, or Number

Metallurgy and Machinability Austempered Ductile Iron (ADI) standard materials

UNS

tensile strength

yield strength

hardness HB

ASTM A897-90

Austempered

n/a

850 MPa (125 ksi) min.

550 MPa (80 ksi) min./elongation 10%

269-321

Ductile Iron (ADI)

n/a

1050 MPa (150 ksi) min.

700 MPa (100 ksi) min./elongation 7%

302-363

125-80-10 150-100-7

n/a

1200 MPa (175 ksi) min.

850 MPa (125 ksi) min./elongation 4%

341-444

175-125-4

n/a

1400 MPa (200 ksi) min.

1100 MPa (155 ksi) min./elongation 1%

388-477

200-155-1

n/a

1600 MPa (230 ksi) min.

1300 MPa (185 ksi) min.

444-555

230-185 Grade, Type, or Number

Compacted Graphite Iron (CGI) standard materials

UNS

tensile strength

yield strength

hardness HB

ASTM A842

Compacted

n/a

250 MPa min.

175 MPa min./elongation 3%

179 Max.

Graphite Iron (CGI)

n/a

300 MPa min.

210 MPa min./elongation 1.5%

143-207

250 300

n/a

350 MPa min.

245 MPa min./elongation 1.0%

163-229

350

n/a

400 MPa min.

280 MPa min./elongation 1.0%

197-255

400

n/a

450 MPa min.

315 MPa min./elongation 1.0%

207-269

450 Grade, Type, or Number

Nickel (Ni) Hard / White Cast Iron standard materials

UNS

properties

hardness HB

ASTM A532 (class)

Austempered

F45000

nickel-chromium irons

550-600

Ductile Iron (ADI)

F45001

nickel-chromium irons

550-600

(I) A, Ni hard (I) B, Ni hard

F45002

nickel-chromium irons

550-600

(I) C, Ni hard

F45003

nickel-chromium irons

400-600

(I) D, Ni hard

F45004

chromium-molybdenum irons

400-600

(II) A, white iron

F45005

chromium-molybdenum irons

400-600

(II) B, white iron

F45006

chromium-molybdenum irons

400-600

(II) C, white iron

F45007

chromium-molybdenum irons

400-600

(II) D, white iron

F45008

chromium-molybdenum irons

400-600

(II) E, white iron

F45009

chromium-molybdenum irons

400-600

(III) A, white iron Grade, Type, or Number

39

Metallurgy and Machinability Cast Iron Cross-Reference / Workpiece Comparison Table UNS

USA

Australia

Belgium

Denmark

France

T150

FGG10 FGG15

GG10 GG15

T220

FGG20

GG20

FGL150 FGL150A FGL200A FGL250A FGL200

FGG25

GG25

FGL250 FGL300A

FGG30

GG30

FGG35

GG35

FGL300 FGL350A FGL400A FGL350

FGG40

GG40

Gray Cast Iron ASTM 48, ASME SA278, ASTM A159, SAE J431 F10004 G1800 F10005 G2500 F10006 F10007 F10008 F11401 F11701 F12101 F12401

G3000 G3500 G4000 20-A 20 25-A 25 30-A 30 35-A 35

F12801 F13101

40-A 45-A 45

F13501

50-A 50 55-A 50 60-A 60

F13801 F14101

FGL400

Gray, Austenitic ASTM A436 F41000 F41001 F41002

1 1b 2

F41003 F41004

2b 3

F41005

4

F41006

5

F41007 Malleable Iron ASTM 602, SAE J158, ASTM A7 F20000

F22200 F22400

40

6

M3210 M4504 M5003 M5503 M7002 M8501 32510 35018

L-NiCuCr1562 L-NiCuCr1563 L-NiCr202 S-NiCr202

L-NUC1562 L-NUC1563 L-NC202 L-NC203

L-NiCr303 S-NiCr303 NiSiCr3055 L-Ni35 S-NiCr353

L-NSC2053 L-NSC3055 L-N35

Metallurgy and Machinability

Germany

Great Britain

International

Italy

Japan

Sweden

Gray Cast Iron ASTM 48, ASME SA278, ASTM A159, SAE J431 Ch130 Ch170

GG-10

Ch190 Ch210 Ch230 G10

100 150

GG-15

100 150 180

FC10-1 FC15-2

GG-20

200

200

G20

FC20-3

220 250 260

250

G25

FC250-4

GG-25 GG-30

300

300

G30

FC25-4 FC30-5

GG-35

350

350

G35

FC350-6

0212-00 0215-00 0217-00 0219-00 0221-00 0223-00 0110-00

G15

0125-00

400 Gray, Austenitic ASTM A436 GGL-NiCuCr1562 GGL-NiCuCr1563 GGL-NiCr202 GGL-NiCr203 GGL-NiCr303

F1 F1 F2 L-NiCr202 F2 F3

GGL-NiSiCr3055

L-NiCuCr1562 L-NiCuCr1563 L-NiCr202

0523-00

L-NiCr203 L-NiCr303 L-NiSiCr2053 L-NiSiCr3055 L-Ni35

S2 Malleable Iron ASTM 602, SAE J158, ASTM A7

41

Metallurgy and Machinability Cast Iron Cross-Reference / Workpiece Comparison Table UNS

USA

Australia

Belgium

370-17

FNG38-17

Denmark

France

Ductile Cast Iron ASTM A395, ASTM A476, ASTM A536, SAE J434

F32800

60-40-18 D4018

715

FGS350-22

716

FGS350-22L FGS400-15 FGS400-18 FGS400-18L

F33100

65-45-12

400-12

FNG42-12

500-7

FNG50-7

D4512 F33101

5315

F33800

80-55-06

727

FGS500-7

D5506 F34100

5316

F34800

100-70-03

700-0

FNG70-2

707

FGS700-2

D7003

800-2

FNG80-2

708

FGS800-2

F36200

120-90-02

FGA900-2

F43000

D-2

S-NC202

F43001

D-2B

Ductile Cast Iron, Austenitic ASTM A439

L-NiCr203

S-NC203

S-NiCr203 F43002

D-2C

F43003

D-3

S-Ni22

S-N22

F43004

D-3A

S-NiCr301

S-NC301

F43005

D-4

S-NiSiCr3055

S-NSC3055

F43006

D-5

S-Ni35

F43007

D-5B

F43010

D-2M-1

S-NC303

S-N35 S-NC353

D-5S

D-2M-2

42

S-NM234

Metallurgy and Machinability

Germany

Great Britain

International

Italy

GS370-17

Japan

Sweden

Ductile Cast Iron ASTM A395, ASTM A476, ASTM A536, SAE J434

GGG-40

350/22

350-22

350/22L40

350-22L

400/18

400-15

0717-02

400-18

0717-15

400/18L20

FCD37-0 FCD40-1

0717-00

400-18L GGG-50

GGG-60

GS400-12

500/7

500-7

GS500-7

FDC45-2

FCD50-3

0727-02

FCD60-4

GGG-70

GGG-80

700/2

700-2

GS700-2

FCD70-5

800/2

800-2

GS800-2

FCD80-6

900/2

900-2

S2

S-NiCr202

Ductile Cast Iron, Austenitic ASTM A439

GGG-NiCr202

S2W GGG-NiCr203

S2B

S-NiCr203

GGG-Ni22

S2C

S-Ni22

GGG-NiCr303

S3

S-NiCr303

GGG-NiCr301

S3

GGG-NiSiCr3055

S-NiCr301 S-NiSiCr3055

GGG-Ni35

S-Ni35

GGG-NiCr353

S-NiCr353

GGG-NiMn234

S2M

S-NiMn234

43

Expert Application Advisor – Cast Irons Gray Cast Iron and Austenitic, Gray Iron (120-320 HB) ASTM: A48I: class 20, 25, 30, 35, 40, 45, 50, 55, 60 ASTM: 126: class A, B, C ASTM: A159 & SAE: J431; G1800, G2500, G3000, G3500, G4000 ASTM: A436; 1, 1b, 2, 2b, 3, 4, 5, 6

Material Characteristics

workpiece breakout

•

out-of-balance condition may exist

•

chucking on cast surface can be difficult

1. Use PVD-coated grade KC5010 at moderate to low speeds.

•

tendency to break out during exit from cut

2. Reduce feed rate during exit.

•

contains abrasive elements; sand may be embedded in the cast surface

3. Pre-chamfer casting edge at exit.

•

potential for chatter on thin wall sections

workpiece chatter

•

corners and thin sections can be chilled (hard and brittle)

1. Use a smaller nose radius.

•

potential scale, inclusions

4. Increase toolholder lead angle.

2. Apply insert geometries that are free-cutting, such as MG-FN and MG-RP. 3. Increase feed to stabilize workpiece.

Common Tool Application Considerations Problems & Solutions

4. Shorten toolholder or bar overhang.

excessive edge wear

5. Check toolholder and workholding system for rigidity.

1. Use grade KC9315 or KT315 if running at moderate to high speeds.

6. Use Top Notch Turning (GX-T style) insert for increased tooling rigidity.

2.. Use silicon nitride-based ceramic grades Kyon 3500 or Kyon 1310, or PCBN grades, if running at ultra-high speeds. Machining system must have the rigidity and horsepower required to run at ultra-high speeds. 3. Increase the feed to reduce in-cut time. chipping 1. Increase toolholder lead angle. 2. Use a grade with good edge strength, such as grade KC9325. 3. Ensure proper insert seating. 4. Use strong, negative-rake insert geometries such as MA, GX-T or GA-T. 5. Use inserts with an MT-land edge prep.

44

Expert Application Advisor – Cast Irons Ductile Iron (120-320 HB) ASTM: A395, A476, A536; 60-40-18, 65-45-12, 80-55-06, 80-60-03, 100-70-03, 120-90-02 SAE: J434; DQ & T, D4018, D4512, D5506, D7003 AMS: 5315, 5316 ASTM: A439. A571; D2, D2B, D2C, D3, D3A, D4, D5, D5B, D2M

Material Characteristics •

graphite is in spherical form, rather than flake form customary in gray cast iron

•

machining difficulties may develop from flank and crater wear on the tool

•

hard spots are common concentrations of carbide in the structure

•

higher tensile strength requires good rigidity in machining system

•

workpiece material structure may vary dramatically

•

decreased tool life should be expected, compared to machining gray or malleable cast iron

Malleable Cast Iron (120-320 HB) ASTM: A47: 32510, 35018 ASTM: A602 & SAE J158; M3210, M4504, M5003, M5503, M7002, M8501 ASTM: A220; 40010, 45008, 45006, 50005, 60004, 70003, 80002, 90001

Material Characteristics •

graphite is in irregular-shaped nodules, rather than flake form customary in gray cast iron

Common Tool Application Considerations Problems & Solutions excessive edge wear 1. Apply grade KC9315 to achieve higher speeds and longer tool life. 2. Use grade KC9325 for general purpose and interrupted cutting. 3. Apply grade KC9315 or KT315 if edge wear is excessive in smooth cuts. 4. Use ceramic grade Kyon 3400. Increase speed and make sure the machining set up and workpart clamping is rigid. 5. Increase feed to reduce time in cut. crater wear

•

generally easy to machine at aggressive conditions.

chipping 1. Use a strong negative-rake insert geometry. Apply the MX-T, GA-T, or MA insert geometry as a first choice; use MG-UN insert geometry as a second choice. 2. Select a T-land or large hone edge prep for greater edge strength. 3. Increase toolholder lead angle. 4. Reduce toolholder or boring bar overhang. 5. Ensure proper insert seating. 6. Apply grade KC9325. 7. Use grade KC9325, increase speed, and decrease feed when cutting with interruptions.

1. Apply grade KC9315 or KT315.

8. Choose grade Kyon 3500 to replace Kyon 3400 for heavy interruptions.

2. Reduce speed to lower the heat at cutting edge.

catastrophic failure

3. Apply ceramic grade Kyon 3400 when machining at high speeds.

1. Reduce speed and feed.

4. Apply large amounts of flood coolant.

torn or dull workpiece

2. Use a T-land plus hone edge prep. 1. Apply insert geometries that are free-cutting surface finish, such as the MG-FN. 2. Use a larger nose radius insert. 3. Use coated cermet grade KT315. 45

Expert Application Advisor – Cast Irons Austempered Ductile Iron (269-444 HB) ASTM: A897; 125-80-10, 150-100-7, 175-125-4, 200-155-1, and 230-185

Material Characteristics •

material is produced by heat treating (austempering) high-quality ductile iron

•

grades 200-155-1 and 230-185 are hard and not recommended for machining with carbide tooling

Austempered ductile irons machine similarly to high-strength ductile irons. Due to the higher strength of these materials, tool life is shortened compared to conventional irons. Use high-strength ductile iron (>80 ksi) machining recommendations for these materials. See KENNA PERFECT recommendations on pages 6-13.

Compacted Graphite Iron (CGI) (179-269 HB) ASTM: A842; Grade 250, 300, 350, 400, 450

Material Characteristics •

graphite is in compacted (vermiform) shapes and relatively free of flake graphite

•

lower hardness levels than gray irons of equivalent strength

•

hard or brittle enough to produce short chips; not hard enough to produce powder

Compacted graphite irons are machined similar to lower-strength ductile irons.

Kennametal Tooling System Solutions KM Kenclamp Tooling Catalog 2014 • Our newest quick-release (1.5 turns) clamping design • Robust clamping design reduces chatter and improves tool life • Ensures insert repeatability and seating • Fewer moving parts vs. competitive systems Request A02-132!

46

Failure Mechanism Analysis Edge Wear*

Corrective Action • Increase feed rate. • Reduce speed (sfm).

Chipping

• Use more wear resistant grade. • Apply coated grade.

• Reduce depth-of-cut (doc). • Use grade with higher hot hardness.

Thermal Cracking

Corrective Action • Properly apply coolant. • Reduce speed.

Corrective Action • Change lead angle. • Consider edge preparation.

• Apply different grade. • Adjust feed.

Built-Up Edge

• Reduce feed. • Apply coated grades.

Crater

Corrective Action • Reduce feed rate. • Reduce speed (sfm).

• Check rigidity of system. • Increase lead angle.

Depth-of-Cut Notching

Heat Deformation

Corrective Action • Reduce speed. • Reduce feed.

Corrective Action • Utilize stronger grade. • Consider edge preparation.

Corrective Action • Increase speed (sfm). • Increase feed rate.

• Apply coated grades or cermets. • Utilize coolant. • Edge prep (smaller hone).

Catastrophic Breakage

• Apply coated grades or cermets. • Utilize coolant.

Corrective Action • Utilize stronger insert geometry grade. • Reduce feed rate.

• Reduce depth-ofcut (doc). • Check rigidity of system.

*NOTE: Generally, inserts should be indexed when .030 flank wear is reached. If it is a finishing operation, index at .015 flank wear or sooner.

47

Machinability Data – Cast Iron Gray Cast Iron

Ductile Cast Iron

The ideal turning insert geometry for machining gray cast iron should have the following characteristics:

The ideal turning insert geometry for machining ductile cast iron should have the following characteristics:

•

square or diamond shaped for maximum strength

•

square or diamond shaped for maximum strength

•

negative insert geometry for maximum strength and number of cutting edges

•

negative insert geometry for maximum strength and number of cutting edges

•

minimum or no positive-rake chip-forming insert geometry for maximum edge strength

•

positive-rake chip-forming insert geometry for freer cutting action and chip control

•

medium edge hone on carbide inserts and a T-land edge prep on ceramic/sialon-grade inserts

•

light edge hone on carbide inserts and a T-land edge prep on ceramic/sialon-grade inserts

Pre-chamfer workpiece whenever possible to avoid workpiece material breakout and interrupted cut shock damage to insert edge.

48

Insert Edge Preparation Edge Preparation for Kennametal’s Advanced Cutting Tool Materials Edge preparation is the term for the intentional modification of the cutting edge of an indexable insert to enhance its performance in a metalcutting operation. Ceramic cutting tool materials have a much higher hardness, but lower toughness, compared to conventional carbide materials. Because of this, ceramic materials have good bulk strength but lower edge strength versus carbide. To optimize performance of ceramic cutting tools, it is critical that tool material, workpiece material, and machining conditions be considered relative to edge preparation. To achieve optimum edge preparation, make the minimum amount of modification necessary to distribute forces sufficiently enough to prevent chipping and catastrophic insert failure. Edge preparations for standard inserts made with specific ceramic grades are determined by target applications and listed in the KENNA PERFECT insert selection system.

There is a tradeoff to the benefits of this edge preparation. Increasing the width “T” of the T-land or the angle “A” increases the overall cutting forces acting on the insert. This can negatively affect the wear rate of the insert and/or deformation of a thin-walled workpiece. For most cast iron turning applications, use a T-land width smaller than the feed rate. For heavily interrupted turning, hard turning (workpiece >50 HRC), and milling applications, use a T-land width larger than the feed rate. 2. Hone Hones protect the insert cutting edge by eliminating the sharp edge and distributing the cutting forces over a larger area. Hones generally are recommended for continuous or finishing operations; however, depending on the workpiece material, they can be used for interrupted or heavy cutting.

There are three choices of edge preparation for ceramic materials:

3. T-land plus hone 1. T-land 2. hone 3. T-land plus hone

In aggressive applications, such as interrupted turning, chipping can occur at the intersection of the T-land and flank surface of the ceramic insert. This condition may be eliminated by applying a small hone to the intersection while leaving the other attributes of the T-land unchanged.

1. T-land T lands protect the insert cutting edge by directing forces into the greater part of the insert, rather than to the smaller cross section of the sharp edge, during the metalcutting process. This helps prevent chipping and catastrophic failure.

49

Chip Control Geometries Kenloc Inserts operation

insert style application

wiper,

feed rate – inches

insert geometry

profile

.0015 .0025 .004 .004 .006 .010

.006 .016

.010 .016 .025 .025 .040 .060

.060 .160

.100 .250

.200 .500

.008 - .016 (0,2 - 0,4)

MG-FW

.010 - .080 (0,3 - 2,0)

finishing

wiper, medium

.040 .100

depth of cut – inches

.012 - .024 (0,3 - 0,6)

MG-MW

.030 - .200 (0,8 - 5,1)

machining

wiper,

MM-RW

roughing

(single sided)

finishing

MG-FN

medium

MG-UN

.010 - .050 (0,3 - 1,3) .050 - .500 (1,3 - 12,7)

.005 - .012 (0,1 - 0,3) .010 - .100 (0,3 - 2,5)

.008 - .020 (0,2 - 0,5) .030 - .150 (0,8 - 3,8)

machining

roughing

MG-RP

roughing

MG-RN

heavy

MM-RM

roughing

(single sided)

.010 - .025 (0,3 - 0,6) .045 - .250 (1,1 - 6,4)

.010 - .025 (0,3 - 0,6) .045 - .250 (1,1 - 6,4)

heavy

MM-RH

roughing

(single sided)

.010 - .040 (0,3 - 1,0) .050 - .500 (1,3 - 12,7)

.015 - .050 (0,4 - 1,3) .050 - .500 (1,3 - 12,7)

feed rate – (mm) 0,04 0,063 0,01 0,1

0,16

0,25

0,16 0,4

0,25

0,4

0,63

1,0

1,6

2,5

5,0

0,63

1,0

1,6

2,5

4,0

6,3

10,0

depth of cut – (mm)

50

Chip Control Geometries Screw-On Inserts operation

insert style/ application

wiper,

feed rate – inches

insert geometry

profile

.0015 .0025 .004

.006

.010 .016

.025

.040

.060

.100

.200

.004

.016

.025 .040

.060

.100

.160

.250

.500

.006

.010

depth of cut – inches .003 - .013 (0,1 - 0,3)

MT-FW

.008 - .060 (0,2 - 1,5)

finishing

wiper, medium

.005 - .020 (0,1 - 0,5)

MT-MW

.016 - .130 (0,4 - 3,3)

machining

fine

.003 - .010 (0,1 - 0,3)

MT-11

finishing

fine

.008 - .050 (0,2 - 1,3)

.002 - .010 (0,1 - 0,3)

MT-UF

.005 - .050 (0,1 - 1,3)

finishing

finishing

MT-LF

medium

MT-MF

.007 - .015 (0,2 - 0,4) .030 - .090 (0,8 - 2,3)

.009 - .017 0,2 - 0,4 .045 - .090 1,1 - 2,3

machining

feed rate – (mm) 0,04 0,063 0,01

0,16

0,25

0,4

0,63

1,0

1,6

2,5

5,0

0,1

0,4

0,63

1,0

1,6

2,5

4,0

6,3

10,0

0,16

0,25

depth of cut – (mm)

51

Kennametal Grade System for Cutting Materials Cermet – (CERamics with METallic binders) grade

coating

KT315

composition and application

composition: A multi-layered, PVD TiN/TiCN/TiN, coated cermet turning grade. application: Ideal for high-speed finishing to medium machining of most carbon and alloy steels and stainless steels. Performs very well in cast and ductile iron applications too. Provides long and consistent tool life and will produce excellent workpiece finishes.

C class ISO class

C3 C7

K10 - K20 M10 - M20 P10 - P20

PVD Coated Carbide Grades grade

coating

KC5010

composition and application

composition: A PVD TiAlN coating over a very deformation-resistant unalloyed, carbide substrate. application: The KC5010 grade is ideal for finishing to general machining of most workpiece materials at higher speeds. Excellent for machining most steels, stainless steels, cast irons, non-ferrous materials and super alloys under stable conditions. It also performs well machining hardened and short chipping materials.

C class ISO class

C3 C4

K10 - K20 M10 - M20 P10 - P20

CVD Coated Carbide Grades grade

coating

KC9315

composition and application

composition: A multi-layered CVD coating with a very thick K-MTCVD layer of TiCN, for maximum wear resistance, is applied over a substrate specifically engineered for cutting cast and ductile irons. application: The KC9315 grade delivers longer tool life when high-speed machining ductile and cast irons. The thick K-MTCVD TiCN coating ensures a tremendous tool life advantage, especially when cutting higher tensile strength ductile and cast irons where workpiece size consistency and reliability of tool life are critical. This new Kennametal grade is excellent when used for either straight or lightly interrupted cut applications. Moreover, if you’re looking for high productivity performance, the KC9315 grade is an ideal choice.

KC9325

composition: A TiCN and alumina-coated grade with a strong, reliable substrate. application: Grade development for the KC9325 grade focused on a variety of ductile and cast iron operations. The coating and substrate are optimized for flexibility. If you are machining different types of ductile or cast irons where application confidence, flexibility and broad range reliability are your primary requirements, the KC9325 grade is the perfect choice.

C class ISO class

C3 - C4 K10 - K25

C2 - C3 K15 - K30

Silicon Nitride-Based Ceramic grade

coating

KY1310*

composition and application

composition: An advanced sialon ceramic grade. application: Grade KY1310 provides maximum wear resistance. Use it for high-speed continuous turning of gray cast iron, including through scale.

C class ISO class

–

K05-K15

C3

K10 - K30

C2

K15 - K35 M15 - M30

*KY1310 will be available January 2004. KY3400

composition: CVD coated pure silicon nitride grade. application: Excellent combination of toughness and edge wear resistance; used for general purpose machining of gray cast irons and ductile or nodular cast irons.

KY3500

composition: Pure silicon nitride grade. application: Maximum toughness; used at high feed rates for rough machining of gray cast iron, including machining through interruptions.

PCBN – Polycrystalline Cubic-Boron Nitride grade

KB9640

52

coating

composition and application

composition: A high CBN content, solid PCBN structure having multiple cutting edges and a CVD alumina coating. application: The KB9640 grade is applied in the roughing to semi-finishing of fully pearlitic gray cast iron, chilled irons, high chrome alloy steels, sintered powdered metals, and heavy cuts in hardened steels (>45 HRC). Use for finished chilled cast iron and fully pearlitic cast iron. Do not apply on finishing hardened steels. KB9640 can be applied effectively when roughing hardened steels.

C class ISO class

C1

K05-K15

Kennametal Grade System for Cutting Materials Gray Cast Irons Ceramic Cutting Tools

Ductile Cast Irons Ceramic Cutting Tools

KY3500“

Carbide Cutting Tools

Carbide Cutting Tools

53

KENNAMETAL

TOOL MANAGEMENT SOLUTIONS No matter how intricate your metalworking manufacturing operations or equipment, Kennametal’s new ToolBoss System, powered by our exclusive, built-to-suit ATMS software, will enable your machinists to spend more time machining parts — far less energy locating tools.

ToolBoss™™ System Our unique, new, easy-to-use/ easy-to-audit tool dispenser can help reduce your: ■

tool-buying costs by as much as 90%!

■

tool-inventory costs by up to 50%!

■

tool-supply costs by nearly 30%!

www.kennametal.com

54

Technical Information page

Wiper Insert Application Guidelines . . . . . . . . . . .

56

Conversion Tables . . . . . . . . . . . . . . . . . . . . . . . . .

60

Nose Radius Selection for Surface Finish . . . . . . . . . . .

61

Insert Size Selection Guide

62

......................

Tool Performance Report Form

....................

Insert Identification System . . . . . . . . . . . . . . . . . . . . . . . .

63 66

55

Three Ways To Improve Your Turning Operations! Kennametal introduces three new geometries that are the latest in state-of-the-art turning technology. Our new -RW (Roughing Wiper), -MW (Medium Wiper) and -FW (Finishing Wiper) inserts employ a modified corner radius design that delivers a superior surface finish compared to conventional inserts. This technology allows you to choose the metalcutting benefit that’s most important to your application.

Double Productivity Kennametal’s new wiper geometries allow you to double your current feed rate and still achieve surface finishes comparable to conventional inserts. You’ll also see equivalent or better tool life using the appropriate KENNA PERFECT grade specifically designed for your workpiece material.

Better Workpiece Finish These new wiper geometries also will give you a markedly improved surface finish at your current machining conditions. Under typical conditions, you’ll see as much as a 250% improvement in the workpiece surface finish, all with inserts that meet your corner radius specifications. You choose! Either way, we’re sure you’ll agree that the new wiper geometries from Kennametal provide an outstanding way to optimize your turning operations. Please see the accompanying information for proper application guidelines.

Kennametal Wiper Technology –MW Conventional Turning Insert doc ............0.050 feed ..........0.012 ipr speed ........1,100 sfm finish ........160 Ra (µin.)

56

doc ................0.050 feed ................0.020 ipr speed..............1,100 sfm finish ..............60 Ra (µ in.)

Negative Wiper Inserts – Application Technology Surface Finish Theoretical Surface Finish – Ra µin. (µm)

insert

feed rate – ipr (mm/rev)

FW , MW, .008 .012 .016 .020 .024 .028 .032 .036 .040 .044 .048 & RW (0,2) (0,3) (0,4) (0,5) (0,6) (0,7) (0,8) (0,9) (1) (1,1) (1,2)

3/8 IC

14 30 50 80 (0,3) (0,75) (1,3) (2)

1/2 IC

—

3/4 + 1 IC

—

—

—

23 41 63 91 120 160 200 250 — (0,6) (1) (1,6) (2,2) (3) (4) (5) (6,2)

—

—

—

—

—

—

—

—

—

103 141 184 232 287 347 413 (2,6) (3,5) (4,6) (5,8) (7,2) (8,7) (10,3)

How It Works Wiper Insert

Standard Insert

LEGEND f – feed r – corner radius rw – wiper radius Ra – surface finish

Corner Radius Configuration CNMG and WNMG wiper inserts create a true corner radius on the workpiece, just as a standard insert does.

DNMG and TNMG wiper inserts do not provide an exact corner radius on the workpiece. The radius produced falls within a ±.0025 tolerance band. (blue lines)

57

Negative Wiper Inserts – Application Technology C– and W–Style Inserts

Kenloc® Toolholders

surface with wiper effect surface with standard insert edge

D– and T–Style Inserts

CN . . 80° corner insert requires MCLN 5° reverse lead angle toolholder

CN . . 100° corner insert requires MCRN 15° lead angle toolholder

CN . . 100° corner insert requires MCKN 15° lead angle toolholder

WN . . 80° corner insert requires MWLN 5° reverse lead angle toolholder

Kenloc Toolholders

surface finish with wiper effect surface with designated insert nose radius surface finish with .016 radius

DN . . 55° corner insert

TN . . 60° corner insert

requires MDJN 3° reverse

requires MTJN 3° reverse

lead angle toolholder

lead angle toolholder

Kenloc Toolholders

S–Style Inserts surface with wiper effect surface with standard insert edge

SN . . 90° corner insert

SN . . 90° corner insert

requires MSRN 15° lead

requires MSKN 15° lead

angle toolholder

angle toolholder

NOTE: The holder guidelines above also apply to ceramic/PCBN wiper inserts in similar insert shapes; i.e.: CNGA, CNGX, DNGA, etc.

58

Positive Wiper Inserts – Application Technology Positive geometry wiper inserts offer the same advantages as negative style inserts. When compared to conventional inserts, feed rates can be doubled while maintaining surface finish, or surface finish can be improved by a multiple of 2.5 while maintaining productive feed rates.

-FW

-MW

Finishing Wiper

Medium Machining Wiper

Surface Finish Theoretical Surface Finish – Ra µin. (µm)

CCMT and CPMT Inserts

insert

feed rate – ipr (mm/rev)

FW , MW

.002 .004 .006 .008 .010 .012 .014 .016 .018 .020 (0,05) (0,10) (0,15) (0,20) (0,25) (0,30) (0,35) (0,40) (0,45) (0,50)

1/4 IC

1 6 14 22 35 49 (0,03) (0,15) (0,35) (0,55) (0,90) (1,25)

—

—

—

3/8 IC

1 4 8 14 22 30 39 — (0,02) (0,10) (0,20) (0,35) (0,55) (0,75) (1,00)

—

—

1/2 IC

1 2 6 10 16 24 31 39 51 63 (0,02) (0,06) (0,15) (0,25) (0,40) (0,60) (0,80) (1,00) (1,30) (1,60)

—

Screw-On Toolholders and Boring Bars

surface with wiper effect surface with designated insert nose radius

C.MT 80° inserts require 5° reverse lead SCL toolholders.

C.MT 100° inserts require 15° lead SCK toolholders.

SDN

SDJ

DCMT– and DPMT–Style Inserts surface finish with wiper effect surface with designated insert nose radius surface finish with .016 radius SDU

D.MT 55° inserts require a 3° reverse lead angle and can be used in SDN, SDU, and SDJ style toolholders and boring bars.

59

Application Guidelines – Cast Iron Conversion Charts hardness Brinell HB

654 634 615 595 577 560 543 525 512 496 481 469 455 443 432 421 409 400 390 381 371 362 353 344 336 327 319 311 301 294 286 279 271 264 258

inch to metric

Rockwell HRB HRC

— — — — — — — — — — — — — — — — — — — — — — — — 109.0 108.5 108.0 107.5 107.0 106.0 105.5 104.5 104.0 103.0 102.5

60 59 58 57 56 55 54 53 52 51 50 49 48 47 46 45 44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26

Brinell HB

253 247 243 237 231 228 222 216 210 205 200 195 190 185 180 176 172 169 165 162 159 156 153 150 147 144 141 139 137 135 132 130 127 125 123

Rockwell HRB HRC

101.5 101.0 100.0 99.0 98.5 98.0 97.0 96.0 95.0 94.0 93.0 92.0 91.0 90.0 89.0 88.0 87.0 86.0 85.0 84.0 83.0 82.0 81.0 80.0 79.0 78.0 77.0 76.0 75.0 74.0 73.0 72.0 71.0 70.0 69.0

25 24 23 22 21 20 18.6 17.2 15.7 14.3 13 11.7 10.4 9.2 8 6.9 5.8 4.7 3.6 2.5 1.4 .30 — — — — — — — — — — — — —

diameter Ø inches mm .315 8,0 .374 9,5 .394 10,0 .472 12,0 .500 12,7 .626 15,9 .630 16,0 .752 19,1 .787 20,0 .874 22,2 .984 25,0 1.000 25,4 1.260 32,0 1.500 38,1 1.968 50,0 2.000 50,8 2.480 63,0 2.500 63,5

Turning Formulas to find

inches .010 .015 .030 .050 .100 .125 .150 .250 .375 .500 feed

60

ipr

mm/rev

.003 .005 .005 .006 .007 .008 .009 .010 .011 .012

.076 .120 .127 .152 .178 .203 .229 .254 .279 .305

sfm 300 400 500 600 800 1000 1200 2000 4000 10000

rpm mpm

sfm ÷ 3.27

sfm

mpm x 3.27

ipr

ipm rpm

ipm

ipr x rpm

mm

inch x 25.4

inches

mm ÷ 25.4

cut time

loc ipr x sfm (minutes)

Abbreviations

speed mm 0,254 0,381 0,762 1,270 2,540 3,175 3,810 6,350 9,525 12,700

formula

d x rpm 3.82 sfm x 3.82 d

sfm

NOTE: Values in shaded areas are beyond normal range and given for information only.

doc

diameter Ø inches mm 3.000 76,2 3.150 80,0 3.500 88,9 3.937 100,0 4.000 101,6 4.921 125,0 5.000 127,0 6.000 152,4 6.299 160,0 7.000 177,8 7.874 200,0 8.000 203,2 9.842 250,0 10.000 254,0 12.000 304,8 12.401 315,0 14.000 355,6 15.748 400,0

m/min. 91 122 152 183 244 305 366 610 1219 3048

surface finish (Ra) µ inch µm 492 12,5 248 6,3 126 3,2 63 1,6 31 0,8 16 0,4

sfm =

surface feet per minute

rpm = mpm =

revolutions per minute meters per minute

ipr = ipm =

inches per revolution inches per minute

d

diameter

=

mm =

millimeters

loc

length of cut

=

Application Guidelines – Cast Iron Nose Radius Selection and Surface Finish for Conventional Inserts*

1

2

3 4

Nose radius and feed rate have the greatest impact on surface finish. To determine the nose radius required for a theoretical surface finish, use the following procedure and the chart above. 1

Locate the required surface finish (rms or AA) on the vertical axis.

2

Follow the horizontal line corresponding to the desired theoretical finish to where it intersects the diagonal line corresponding to the intended feed rate.

3

Project a line downward to the nose radius scale and read the required nose radius.

4

If this line falls between two values, choose the larger value.

NOTE: Peaks produced with a small radii insert (top) compared to those produced with a large radius insert (bottom).

• If no available nose radius will produce the required finish, feed rate must be reduced. • Reverse the procedure to obtain surface finish from a given nose radius. *NOTE: See pages 57-59 for radius and surface finish specifications using wiper-style inserts.

61

Insert Size Selection Guide Cast Iron Geometries maximum depth of cut

insert shape

IC

cutting edge length

finishing MG-FN MG-FW MA-T0820 T0420-FW

.250 .375 .500 .625 .750 1.000 .250 .375 .500 .625

.250 .375 .500 .625 .750 1.000 .275 .433 .590 .748

R-Round

.375 .500 .625 .750 1.000

.188 .250 .313 .375 .500

S-Square

.375 .500 .625 .750 1.000

.375 .500 .625 .750 1.000

..075 ..120

T-Triangle

.250 .375 .500 .625

.433 .630 .866 1.060

.030 .060 .100

V-35° Diamond

.375 .500

.630 .866

W-Trigon

.250 .375 .500

.157 .236 .315

C-80° Diamond

D-55° Diamond

62

.050 .075 .120

general purpose MG-UN MG-RP MG-MW

roughing MX-T0820 ..MA – S0820

.150 .250 .313 .375 .500

.250 .313 .375 .500

.125 .175

.150 .200

.112 .200 .250 .300 .400

.112 .200 .250 .300 .400

.150 .250 .313 .375 .500

.150 .250 .313 .375 .500

.125 .175 .250

.150 .200 .300

.045

.060

.070 .120

.075 .100

.100 .150

.120 .200

.030 .060 .100

Turning Tool Performance Report COMPANY & LOCATION

DATE

ENGINEER

CUSTOMER NAME

MATERIAL TYPE AND CONDITION

PART DESCRIPTION

CUTTING CONDITION (CIRCLE)

HARDNESS

MACHINE & TYPE

OPERATION

CONDITION OF MACHINE

HP

CONSTANT SFM ■ YES

■ NO

PART CONFIGURATION COMMENTS

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28

PERFORMANCE, TECHNICAL & COST DATA OPERATION NUMBER TURRET POSITION TOOLHOLDER INSERT STYLE GRADE DEPTH OF CUT LENGTH OF CUT FEED RATE (IPR) WORKPIECE DIAMETER CUTTING SPEED

TEST 1

TEST 2

TEST 3

RPM SFM CUTTING TIME PER PIECE (MINUTES) (30 SECONDS = .5) PIECES PER EDGE CUTTING TIME PER EDGE (MINUTES) (11 x 12) CUTTING EDGES PER INSERT PIECES PER INSERT (14 x 12) REASONS FOR INDEXING TYPE OF COOLANT HORSEPOWER REQUIRED FINISH (RMS) CHIP CONTROL (GOOD, FAIR, POOR) INSERT COST INSERT COST PER PIECE (21 ÷ 15) MACHINE COST PER HOUR MACHINE COST PER PIECE (11 x 23 ÷60) TOTAL COST PER PIECE (24 + 22) ESTIMATED ANNUAL PRODUCTION – PIECES ESTIMATED ANNUAL COST (26 x 25) ESTIMATED ANNUAL SAVINGS

63

KENNA PERFECT Inserts Steel Stainless Steel Cast Iron Non-Ferrous Metals High-Temperature Alloys Hardened Materials

64

Table of Contents page Insert Identification System . . . . . . . . . . . .

66

Kenloc® Negative Inserts . . . . . . . . . . . . . . . .

68

Screw-On Inserts . . . . . . . . . . . . . . . . . . . . . . .

81

Top Notch® Turning Inserts . . . . . . . . . . . . . . . . .

91

Kendex® Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . .

94

65