Tools, tips & productivity
Hard Part Turning SPK-WURBON® for Machining of Hardened Steel
Hard turning with SPK-WURBON®
3
SPK-WURBON® (CBN) is the ideal cutting material for machining hardened steel featuring a hardness of up to 68 HRC. It allows for achieving top surface qualities and maximum efficiency in finish hard turning.
SPK- WURBON®
Hard turning is used at an increasing
used must be superior by particular pro-
rate to produce high-quality components
perties.
which must comply with high require-
Such properties are: high resistance to
ments towards dimensional and shape ac-
wear and high material and red hardness
curacy. Grinding processes are either
in combination with high compressive
wholly or partly replaced by hard turning
strength and chemical stability. These pro-
operations for reasons of efficiency and
perties have a substantial effect on the
ecology.
quality of the workpiece. The tool life and
In order to comply with the high demands
the surface quality achieved substantially
of hard turning, the cutting materials
depend on the insert's cutting edge.
Low CBN content 45–65 %
Classification of the SPK-WURBON® cutting materials
(ISO classification: BL) Key application: Hard turning of steel with a hardness of 55-68 HRC.
SPK-WURBON® grades offer these properties, and hence are ideally suited for finish-machining of hardened steel.
The range of applications of SPK-
For hard turning of steel materials fea-
WURBON® grades varies depending on
turing a hardness of up to 68 HRC, gra-
the grade's content of CBN and binder, as
des with CBN contents of approx.
WBN 555, WBN 560, WBN 570,
well as on its grain size and grain size dis-
45 - 65% are recommended.
WBN 575
tribution.
SPK-WURBON®
grades
Applications of SPK-WURBON® when hard turning (50-68 HRC) Grade
continuous cut stable conditions
continuous cut unstable conditions
WBN 555
light
Intermittent cuts medium heavy
WBN 570
WBN 575
WBN 560
Main application
Additional application
Info The grades were designed for dry machining. Nevertheless, they can also be used with coolants.
Customized Special Solutions
4 SPK Cutting Tools also provides en-
For grooving of hardened materials, spe-
gineering services when it comes to desi-
cial geometries on the basis of CBN full fa-
gning special tools and special inserts. Too-
ce laminated SPK-WURBON ® grades are
ling and process solutions are designed in
designed and produced.
a way to provide optimum machining results and top efficiency at a time.
Special tool for machining of synchronizing ring
Applications of the SPK-WURBON® grades WBN 555 is the top grade for machining operations on hardened steel performed with highly interrupted cuts and using a cutting speed of vc = 80 - 160 m/min. It is also used for machining of sintered steel and hard metals.
WBN 560 is particularly suited for hard turning performed from light to moderate interruptions or under unfavourable machining conditions in continuous cutting. It is used with cutting speeds of vc = 100 - 160 m/min.
WBN 575
WBN 560
Wear resistance
WBN 570
WBN 570 is suited for a wide range of hard machining applications owing to its balanced combination of toughness and wear resistance. It is suited for hard turning performed with continuous cutting, and for machining operations performed with moderate interruptions. For this grade, the ideal cutting speed ranges at vc = 120 - 180 m/min. WBN 575 represents a high-performance grade with excellent wear resistance. Owing to its fine-grained structure, this grade particularly allows for complying with the highest demands in respect of surface quality and dimensional accuracy. It is mainly used for hard turning performed with continuous cutting and high cutting speeds under stable machining conditions. The ideal cutting speed range for this grade is vc = 140 - 250 m/min.
WBN 555
Toughness Applications of the SPK grades in hardened steel (55–68 HRC)
Types of SPK-WURBON® inserts ISO 1832 5 Symbol
Illustration
SPK-WURBON® grades
Description
one-side, multi-tipped CBN inserts, 2 corners
WBN 555 WBN 560 WBN 570 WBN 575
one-side, multi-tipped CBN inserts, 3 corners
WBN 555 WBN 560 WBN 570 WBN 575
D
one-side, multi-tipped CBN inserts, 4 corners
WBN 555 WBN 560 WBN 570 WBN 575
F
CBN one-sided full face laminated
WBN 560 WBN 570 WBN 575
B
C
Types of cutting edges
Apart from the SPK-WURBON® grade of which the individual inserts are made, the insert's chamfer geometry should be considered since it is of decisive importance in respect of machining results. The chamfer geometry will not only influence the toollife, but also the surface quality and dimensional accuracy of the workpiece.
Chamfer
Application
T
First choice for hard turning performed with either continuous or interrupted cuts when hard turning.
S For specific applications, optimizing the chamfer may cause a supplementary increase in productivity.
chamfered
chamfered + rounded
The chamfered and rounded cutting edges offer supplementary stability under severe machining conditions.
ZZ geometry for improved surface quality and higher feed rate 6 Every oak has been an acorn - this probably is the best way to describe
Standard geometry
ZZ geometry 2xf
f
ning when using the ZZ geometry as wiper geometry.
R th
re
Using cutting inserts with ZZ geo-
re
th
Rw
z
which in the trade is also referred to
R
ce which can be achieved in finish-tur-
Rw
the enormous increase in performan-
metry allows for significantly higher surface qualities to be achieved in
z
comparison with inserts featuring standard geometries. Alternatively, main machining times can be reduced considerably without any consequen-
Equal feed rate = doubled surface quality
ces to high surface qualities.
Increase in production quality
or
Hence, the ZZ geometries represent one of the most efficient ways of in-
Doubled feed rate = machining times cut down by half
Increase in productivity
creasing productivity in machining and especially in finishing operations. The standard range of inserts with ZZ geometry covers almost any hard turning application. For achieving further increases in productivity and for optimizing individual machining operations, SPK additionally offers customized designs.
Designation system for SPK-WURBON® inserts Length of the CBN element Code letter Dimension l1 (mm)
S
L
−> 0,8
−> 2,0 one-side, multi-tipped CBN inserts, 2 corners length of the CBN insert − > 2,0 mm
Example: CCGW 09T308 T-BL95Z025 chamfered
width of the ZZ chamfer = 0.25mm entering angle = 95°
Classification of SPK-WURBON® grades ISO 513 7
BL - H25 BL - H15 BL - H10 BL - H05
Preferred application area
H
01
10
20
30
40
Type of machining
Grooving
S
Range of applications
Turning
Workpiece materials
Had materials
WBN 555 WBN 560 WBN 570 WBN 575
Standard designation
Special alloys and titanium
Grade
T
G
Range of application
= Main application, = Additional application
f (mm)
140 – 250 140 – 200 120 – 170 100 – 150
0,1–0,5 0,1–0,5 0,1–0,5 0,1–0,5
0,05–0,20 0,05–0,20 0,05–0,20 0,05–0,20
180 – 300 200 – 350 250 – 400
1,0–2,5 0,5–1,5 0,1–1,0
0,20–0,30 0,10–0,25 0,10–0,20
WBN 575
ap (mm)
WBN 560
vc (m/min)
WBN 555
SPK-WURBON® grades
WBN 570
Recommendations for SPK-WURBON® grades
Hardened steel (50-68 HRC) continuous cut light intermittent cut medium intermittent cut heavy intermittent cut
Sintered metals Semi-roughing Finishing Fine finishing = Recommendation, = Alternative For machining sintered steel, SPK-WURBON® grades with high CBN content (ISO BH classification) can be used also depending on the material to be machined.
Machining examples
8
Machining of geared shaft end using the grade WBN 555 Geared shaft end Machining of geared shaft end using the grade WBN 555 Machining operation: turning geared shaft end Material: 30Mn5V Hardness: 56 HRC Reequirements: heavy interrupted cut Coolant: none Grade:
WBN 555
Insert:
CNGA 120408 S-BL
Cutting speed vc :
150 m/min
Feed rate f:
0.27 mm
Depth of cut ap:
0.15 mm
Tool-life N:
100 pcs.
Machining of ring gear using the grade WBN 560 Ring gear Machining of ring gear using the grade WBN 560 Machining operation: bore turning Material: 20MnCr4 E Hardness: 58-62 HRC Requirement: Rz 10 / IT 6 Coolant: none Grade:
WBN 560
Insert:
CNGA 120408 T-BL95Z025
Cutting speed vc: Feed rate f:
170 m/min 0.12 mm
Depth of cut ap:
0.15 mm
Tool-life N:
1800 pcs.
Machining examples
9
Machining of speed variator disk using the grade WBN 570 Speed variator disk Machining of speed variator disk using the grade WBN 570 Machining operation: preturning Material: 15CrMo5 Hardness: 62 HRC Coolant: none Grade:
WBN 570
Insert:
CNGA 120412 T-BL
Cutting speed vc: Feed rate f: Depth of cut ap: Tool-life N:
130 m/min 0.3 mm 0.2-0.3 mm 150 pcs.
Machining of axle shaft using the grade WBN 570 Axle shaft Machining of axle shaft using the grade WBN 570 Machining operation: Bearing seat Material: 42CrMo4 Requirements: IT6 Coolant: none Grade:
WBN 570
Insert:
CNGA 120408 T-BL
Cutting speed vc:
190 m/min
Feed rate f:
0.22 mm
Depth of cut ap:
0.15 mm
Tool-life N:
80 pcs.
Hardness: 56 HRC
SPK-WURBON® multi-tipped CBN inserts bei Gusseisen und gehärtetem Stahl on cast iron and hardened steel
10 Insert
ISO
Grade
SPK ref. no.
CCGW 0602 .. - BL
CCGW 06 02 02 T - BL
WBN 570
22.57.405.44.4
CCGW 06 02 04 S - BL
WBN 560
22.57.406.46.2
CCGW 06 02 04 T - BL
WBN 570 WBN 575
22.57.406.44.4 22.57.406.44.5
CCGW 09 T3 04 S - BL
WBN 560
22.57.401.46.2
CCGW 09 T3 04 T - BL
WBN 570 WBN 575
22.57.401.44.4 22.57.401.44.5
CCGW 09 T3 08 S - BL
WBN 560
22.57.402.46.2
CCGW 09 T3 08 T - BL
WBN 570 WBN 575
22.57.402.44.4 22.57.402.44.5
CCGW 09 T3 08 S - BL 95Z025
WBN 560
22.57.407.46.2
CCGW 09 T3 08 T - BL 95Z025
WBN 570 WBN 575
22.57.407.44.4 22.57.407.44.5
CNGA 12 04 04 S - BL
WBN 555 WBN 560
22.56.406.46.1 22.56.406.46.2
CNGA 12 04 04 T - BL
WBN 570 WBN 575
22.56.406.44.4 22.56.406.44.5
CNGA 12 04 08 S - BL
WBN 555 WBN 560
22.56.406.46.1 22.56.406.46.2
CNGA 12 04 08 T - BL
WBN 570 WBN 575
22.56.406.44.4 22.56.406.44.5
CNGA 12 04 12 S - BL
WBN 555 WBN 560
22.56.408.46.1 22.56.408.46.2
CNGA 12 04 12 T - BL
WBN 570 WBN 575
22.56.408.44.4 22.56.408.44.5
80
r
2.8
6.35
7°
°
6.4
2.38
CCGW 09T3 .. - BL 7°
80
r
4.4
9.52
°
9.7
3.97
80
9.7
7°
CCGW 09T3 .. - BL 95Z025
0.25
3.97
5°
.8
4.4
9.52
0.25
°
r0
CNGA 1204 .. - BL 80
5.16
12.7
°
r 12.9
4.76
SPK-WURBON® multi-tipped CBN inserts bei Gusseisen und gehärtetem Stahl on cast iron and hardened steel
11 Insert
ISO
Grade
SPK ref. no.
CNGA 1204 .. - BL - 95Z025
CNGA 12 04 08 S - BL 95Z025
WBN 560
22.54.496.46.2
CNGA 12 04 08 T - BL 95Z025
WBN 570 WBN 575
22.54.496.44.4 22.54.496.44.5
DCGW 07 02 04 T - BL
WBN 570 WBN 575
22.57.410.44.4 22.57.410.44.5
DCGW 07 02 08 T - BL
WBN 570 WBN 575
22.57.411.44.4 22.57.411.44.5
DCGW 11 T3 04 S - BL
WBN 555 WBN 560
22.57.408.46.1 22.57.408.46.2
DCGW 11 T3 04 T - BL
WBN 570 WBN 575
22.57.408.44.4 22.57.408.44.5
DCGW 11 T3 08 S - BL
WBN 555 WBN 560
22.57.409.46.1 22.57.409.46.2
DCGW 11 T3 08 T - BL
WBN 570 WBN 575
22.57.409.44.4 22.57.409.44.5
DNGA 15 04 04 S - BL
WBN 555
22.56.401.46.1
DNGA 15 04 04 T - BL
WBN 570
22.56.401.44.4
DNGA 15 04 08 S - BL
WBN 555
22.56.402.46.1
DNGA 15 04 08 T - BL
WBN 570
22.56.402.44.4
DNGA 15 04 08 T - BL
WBN 750
16.56.402.37.8
°
5.16
80
12.7
0.25
12.9
.8
4.76
5°
r0
0.25
55
7°
DCGW 0702 .. - BL
2.8
6.35
°
r
7.75
2.38
55
7°
DCGW 11T3 .. - BL
9.52
° 4.4
r 11.6
3.97
DNGA 1504 .. - BL
15.5
5.16
12.7
55°
r
4.76
SPK-WURBON® multi-tipped CBN inserts bei Gusseisen und gehärtetem Stahl on cast iron and hardened steel
12 ISO
Grade
SPK ref. no.
DNGA 1506 .. - BL
DNGA 15 06 04 S - BL
WBN 555
22.56.403.46.1
DNGA 15 06 04 T - BL
WBN 570
22.56.403.44.4
DNGA 15 06 08 S - BL
WBN 555 WBN 560
22.56.405.46.1 22.56.405.46.2
DNGA 15 06 08 T - BL
WBN 570 WBN 575
22.56.405.44.4 22.56.405.44.5
DNGA 15 06 12 S - BL
WBN 555 WBN 560
22.56.411.46.1 22.56.411.46.2
DNGA 15 06 12 T - BL
WBN 570 WBN 575
22.56.411.44.4 22.56.411.44.5
SCGW 09 T3 04 S - DL
WBN 560
22.17.419.46.2
SCGW 09 T3 04 T - DL
WBN 570 WBN 575
22.17.419.44.4 22.17.419.44.5
SCGW 09 T3 08 S - DL
WBN 560
22.17.420.46.2
SCGW 09 T3 08 T - DL
WBN 570 WBN 575
22.17.420.44.4 22.17.420.44.5
SNGA 12 04 04 S - DL
WBN 555
22.16.401.46.1
SNGA 12 04 04 T - DL
WBN 570 WBN 575
22.16.401.44.4 22.16.401.44.5
SNGA 12 04 08 S - DL
WBN 555
22.16.402.46.1
SNGA 12 04 08 T - DL
WBN 570 WBN 575
22.16.402.44.4 22.16.402.44.5
SNGA 12 04 12 S - DL
WBN 555 WBN 560
22.16.403.46.1 22.16.403.46.2
SNGA 12 04 12 T - DL
WBN 570 WBN 575
22.16.403.44.4 22.16.403.44.5
r
5.16
12.7
55°
Insert
6.35
15.5
r 9.52
4.4
7°
SCGW 09T3 .. - DL
3.97
5.16
SNGA 1204 .. - DL
r 12.7
4.76
SPK-WURBON® multi-tipped CBN inserts bei Gusseisen und gehärtetem Stahl on cast iron and hardened steel
13 ISO
Grade
SPK ref. no.
TCGW 0902 .. - CL
TCGW 09 02 04 S - CL
WBN 555 WBN 560
22.37.405.46.1 22.37.405.46.2
TCGW 09 02 04 T - CL
WBN 570 WBN 575
22.37.405.44.4 22.37.405.44.5
TCGW 11 02 04 S - CL
WBN 555 WBN 560
22.37.403.46.1 22.37.403.46.2
TCGW 11 02 04 T - CL
WBN 570 WBN 575
22.37.403.44.4 22.37.403.44.5
TCGW 11 02 08 S - CL
WBN 555
22.37.404.46.1
TCGW 11 02 08 T - CL
WBN 570
22.37.404.44.4
TNGA
16 04 04 S - CL
WBN 555 WBN 560
22.36.401.46.1 22.36.401.46.2
TNGA
16 04 04 T - CL
WBN 570 WBN 575
22.36.401.44.4 22.36.401.44.5
TNGA
16 04 08 S - CL
WBN 555 WBN 560
22.36.402.46.1 22.36.402.46.2
TNGA
16 04 08 T - CL
WBN 570 WBN 575
22.36.402.44.4 22.36.402.44.5
TNGA
16 04 12 S - CL
WBN 555 WBN 560
22.36.403.46.1 22.36.403.46.2
TNGA
16 04 12 T - CL
WBN 570 WBN 575
22.36.403.44.4 22.36.403.44.5
r 9.62
2.8
5.5
6
60°
7°
Insert
2.38
6.3
5
60°
7°
TCGW 1102 .. - CL
2.8
r
2.38
11.0
TNGA 1604 .. - CL
3.81
9.5
2
60°
r 16.5
4.76
SPK-WURBON® multi-tipped CBN inserts bei Gusseisen und gehärtetem Stahl on cast iron and hardened steel
14 ISO
Grade
SPK ref. no.
VBGW 1604 .. - BL
VBGW 16 04 04 S - BL
WBN 555 WBN 560
22.57.412.46.1 22.57.412.46.2
VBGW 16 04 04 T - BL
WBN 570 WBN 575
22.57.412.44.4 22.57.412.44.5
VBGW 16 04 08 S - BL
WBN 555 WBN 560
22.57.413.46.1 22.57.413.46.2
VBGW 16 04 08 T - BL
WBN 570 WBN 575
22.57.413.44.4 22.57.413.44.5
VBGW 16 04 12 S - BL
WBN 555 WBN 560
22.57.414.46.1 22.57.414.46.2
VBGW 16 04 12 T - BL
WBN 570 WBN 575
22.57.414.44.4 22.57.414.44.5
VNGA 16 04 04 S - BL
WBN 560
22.56.409.46.2
VNGA 16 04 04 T - BL
WBN 570 WBN 575
22.56.409.44.4 22.56.409.44.5
VNGA 16 04 08 S - BL
WBN 560
22.56.410.46.2
VNGA 16 04 08 T - BL
WBN 570 WBN 575
22.56.410.44.4 22.56.410.44.5
35
Insert
5° 4.4
9.52
°
r 16.6
4.76
VNGA 1604 .. - BL 35
16.6
3.81
9.52
°
r
4.76
SPK-WURBON® laminated CBN inserts bei Gusseisen und gehärtetem Stahl on cast iron and hardened steel
15 ISO
Grade
SPK ref. no.
RBGN 1204 MO - F
RBGN 12 04 MO S - F
WBN 570
22.41.243.31.8
RNMN 09 03 00 S - F
WBN 560
22.40.208.46.2
RNMN 09 03 00 T - F
WBN 575
22.40.208.44.5
RNMN 12 04 00 T - F
WBN 570
22.40.203.44.4
5°
Insert
12.0
4.76
RNMN 0903 00 - F
9.52
3.18
RNMN 1204 00 - F
12.7
4.76
A small part. A big impression! This small indexable insert embodies our never-ending endeavor to supply CeramTec customers in the automotive, metalworking and mechanical engineering industries with cutting-edge advantages in turning, milling and boring. Through added reliability, enhanced quality, and shorter production cycles, SPK can help reduce your production costs. In other words: generating added value for our customers is our uppermost goal. What’s more: such achievements on the part of our materials and tools are possible without any need for coolant—for the benefit of their users, the environment, and of course your budget. Talk to us to find out more about the added value inherent in high-performance machining of cast iron and hardened steel.
CeramTec AG Innovative Ceramic Engineering Business Unit SPK Cutting Tools Gottlieb-Haefele-Strasse 7 D-73061 Ebersbach/Fils Phone +49 – 71 63 – 1 66 239 Fax +49 – 71 63 – 1 66 388
[email protected] www.ceramtec.com
864.3 · D · 2000 · 5090 · DD · Printed in Germany WZ 37.70.91.49.8
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