The new standard for hardened steel machining

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Gervais Paul
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1 Keeping the Customer First Tungaloy Report No. 388-E New coated CBN grade for hardened steel turning NEW The new standard for hardened steel machining

f (mm/rev) 2 (15-35).1 (.5 -.3).1 (.3 -.

2 New coatedcbn grades BXMseries Applicable for all types of hard NEW For high speed machining NEW All-round Excellent crater wear resistance! Continuous cutting Newly developed CBN substrate for high speed cutting! cutting condition Application Grades Machining Mode Hard Materials Continuous Light interrupted Continuous Interrupted Cutting speed Depth of cut Feed Vc (m/min) ap (mm) f (mm/rev) 2 (15-35).1 (.5 -.3).1 ( ) 17 (15-25).1 (.5 -.3).1 ( ) 15 (7-22).2 (.5 -.3).1 ( ) 15 (7-22).1 (.5 -.3).1 ( ) 2

ned steel turning Comparison of damage Continuous cutting New coating layer Interrupted cutting

speedvc (m/min) 3 2 1 Continuous Light Interrupted Hard Materials Heavy Cutting speed Feed Depth of

15 mm : Water soluble Cutting performance Tool life (competitor: 1) 6 5 4 3 2 1 5 times longer tool

3 ned steel turning Comparison of damage Continuous cutting New coating layer Interrupted cutting Remarkable adhesion strength Unique CBN substrate High chipping resistance!! Extremely tough Substrate!! Application range BMX2 has normal wear pattern without peeling Normal wear Peeling Cutting speedvc (m/min) Continuous Light Interrupted Hard Materials Heavy Cutting speed Feed Depth of cut : 2QP-CNGA1248 : SCM415H (6HRC) : Vc = 13 m/min : f =.15 mm/rev : ap =.15 mm : Water soluble Cutting performance Tool life (competitor: 1) times longer tool life! Interrupted cutting Removing carburized layer Continuous cutting Vc = 13 m/min f =.15 mm/rev ap =.15 mm Vc = 11 m/min f =.12 mm/rev ap =.6 mm Vc = 13 m/min f =.15 mm/rev ap =.15 mm : 2QP-CNGA1248 : SCM415H : Water soluble 3

Cutting performance High speed machining comparisons (Vc =

flank wear width: VBmax (mm).15.1 Chipping Chipping.

speed Feed Depth of cut Work process : 2QP-CNGA1248 :

25 mm : Continuous cutting : Dry Comparison of wear

SCM415H (59 ~ 61HRC) : Vc = 13 m/min : f =.

15 mm : Continuous cutting : Water soluble Comparison of

interrupted cutting Cutting time: T (min) 4 3 19 1 Cutting

4 Cutting performance High speed machining comparisons (Vc = 3 m/min) Continuous cutting Max. flank wear width: VBmax (mm).15.1 Chipping Chipping.5 Conventional Cutting time: T (min) Cutting speed Feed Depth of cut Work process : 2QP-CNGA1248 : SCM415H (59 ~ 61HRC) : Vc = 3 m/min : f =.1 mm/rev : ap =.25 mm : Continuous cutting : Dry Comparison of wear resistance Continuous cutting Max. flank wear width: VBmax (mm) Conventional Cutting time: T (min) Cutting speed Feed Depth of cut Work process : 2QP-CNGA1248 : SCM415H (59 ~ 61HRC) : Vc = 13 m/min : f =.15 mm/rev : ap =.15 mm : Continuous cutting : Water soluble Comparison of toughness After 19 minutes After 19 minutes Light interrupted cutting Cutting time: T (min) Cutting speed Feed Depth of cut Work process : 2QP-CNGA1248 : SCM415H (59 ~ 61HRC) : Vc = 13 m/min : f =.15 mm/rev : ap =.15 mm : Light interrupted cutting : Water soluble 4

Hard Breakers for removing the carburized layer Two types of chipbreaker provide excellent chip control in a wide application range!

Excellent chip control in small DoC due to the high functional nose. Delivers exceptional surface finishes. Depth of cut: ap (mm).25.5.75 1. HFChipbreaker.5.1.15.

Providing ideal chip control in large DoC by the well designed chipbreaker. Suitable for medium cutting or roughing. Depth of cut: ap (mm).25.5.75 1.

5 Hard Breakers for removing the carburized layer Two types of chipbreaker provide excellent chip control in a wide application range! HF type For finishing Example of chips Single sided CBN insert provides higher stability in heavy machining. Excellent chip control in small DoC due to the high functional nose. Delivers exceptional surface finishes. Depth of cut: ap (mm) HFChipbreaker Feed: f (mm/rev) HM type For medium cutting Example of chips Single sided CBN insert provides higher stability in heavy machining. Providing ideal chip control in large DoC by the well designed chipbreaker. Suitable for medium cutting or roughing. Depth of cut: ap (mm) HFChipbreaker Feed: f (mm/rev) cutting condition (for removing the carburized layer) Application Grades Chipbreaker Cutting speed Depth of cut Feed Vc (m/min) ap (mm) f (mm/rev) Hard Materials HF 15 (7-22).4 ( ).1 (.5 -.2) HM 15 (7-2).7 (.5-1.).1 (.5 -.2) 5

6 Wiper edge inserts A finishing edge (wiper edge) is formed at the point of intersection between the corner radius and the straight cutting edge. Effect of wiper edge Doubles the productivity Reduced machining time The wiper edge can double the feed rate and suppresses deterioration of the surface finish. f.3mm/rev Superior surface finishes By integrating roughing and finishing into one process, the productivity can be increased. Compared with conventional inserts, surface roughness can be improved with the wiper edge. corner R Wiper edge geometry Wiper edge Comparison of surface finish with hardened steel at 6-62 HRC Without wiper Ra:.83 µm,rz: 4.11 µm With wiper edge Ra:.1 µm,rz: 1.3 µm Cutting speed Feed Depth of cut : 2QP-CNGA1248WL : SCM415 (62HRC) : Vc = 15 m/min : f =.1 mm/rev : ap =.15 mm : Dry Note for using of wiper edge The wiper edge needs to contact the work piece at a right angle. For the wiper edge, the toolholder should have an end cutting angle as shown in the illustration. In using the wiper edge a high rigidity toolholder like the Turning-A or D-type is recommended. In the table below, recommended toolholders are shown. End cutting angle End cutting angle, recommended toolholders End cutting angle External toolholder Internal toolholder 2QP-CNGA124**WL 3QP-WNGA848WL 2QP-DNGA154**WJ 3QP-TNGA164**WG ACLNR/L*****12-A AWLNR/L*****8-A ADJNR/L*****15-A ATGNR/L*****16-A ATFNR/L*****16-A DCLNR/L*****12 DWLNR/L*****8 DDJNR/L*****15 DTGNR/L*****16 DTFNR/L*****16 A***-ACLNR/L12-D*** A***-AWLNR/L8-D*** A***-ADUNR/L15-D*** A***-ATFNR/L16-D*** 6

7 Designation System - CNGA QP WL 4 1 Number of edge 2 Type 3 ISO symbols T-CBN (Based on ISO standard) QP 2 TAC insert 3 Honing specification -L -H :.13 mm 25 +R- :.13 mm 15 +R- :.13 mm 35 +R- 4 Additional symbol Light -L for low cutting force Heavy -H for toughness Wiper edge, WG 91 end cutting angle Wiper edge, WJ 93 end cutting angle Wiper edge, WL 95 end cutting angle 4 Chipbreaker symbol -HF -HM For finishing For medium cutting to roughing Smaller angle makes the edge sharper with lower cutting forces. Larger angle makes edge tougher. 7

8 s(negative type) Features Shape Cat. No. Grades Dimensions (mm) No. of I.C.dia Thickness Hole dia Corner R CBN length corners ød s ød1 rε a 2QP-CNGA QP-CNGA QP-CNGA QP-CNGA1244-L Light 2QP-CNGA1248-L QP-CNGA12412-L QP-CNGA1244-H Heavy 2QP-CNGA1248-H QP-CNGA12412-H QP-CNGA1244WL Wiper edge 2QP-CNGA1248WL QP-CNGA12412WL QP-DNGA QP-DNGA QP-DNGA QP-DNGA QP-DNGA QP-DNGA QP-DNGA1544-L Light 2QP-DNGA1548-L QP-DNGA15412-L QP-DNGA1544-H Heavy 2QP-DNGA1548-H QP-DNGA15412-H Wiper edge 2QP-DNGA1544WJ QP-DNGA1548WJ QP-SNGA QP-SNGA QP-SNGA Light 2QP-SNGA1248-L QP-SNGA12412-L Heavy 2QP-SNGA1248-H QP-SNGA12412-H QP-TNGA QP-TNGA QP-TNGA QP-TNGA1644-L Light 3QP-TNGA1648-L QP-TNGA16412-L QP-TNGA1644-H Heavy 3QP-TNGA1648-H QP-TNGA16412-H Wiper edge 3QP-TNGA1644WG QP-TNGA1648WG QP-VNGA QP-VNGA QP-VNGA Light 2QP-VNGA1644-L QP-VNGA1648-L Heavy 2QP-VNGA1644-H QP-VNGA1648-H QP-WNGA Wiper edge 3QP-WNGA848WL : Stockeditems : Coming soon 8

9 s(negative type with chipbreaker) Features Shape Cat. No. Grades Dimensions (mm) No. of I.C.dia Thickness Hole dia Corner R CBN length corners ød s ød1 rε a 2QP-CNGM1248-HF QP-CNGM12412-HF QP-DNGM1548-HF With 2QP-DNGM15412-HF chipbreaker 3QP-TNGM1648-HF QP-TNGM16412-HF QP-VNGM1648-HF With chipbreaker 2QP-CNGM1248-HM QP-CNGM12412-HM QP-DNGM1548-HM QP-DNGM15412-HM QP-TNGM1648-HM QP-TNGM16412-HM QP-VNGM1648-HM s(positive type) Features Shape Cat. No. Grades Dimensions (mm) No. of Relief corners angle ød ød s ød1 rε a 2QP-CCGW QP-CCGW QP-CCGW9T QP-CCGW9T QP-DCGW QP-DCGW QP-DCGW11T QP-DCGW11T QP-DCGW11T QP-TPGW QP-TPGW QP-TPGW QP-TPGW QP-TPGW QP-TPGW QP-TPGW QP-TPGW QP-TPGW QP-TPGW QP-TPGW16T QP-TPGW16T QP-TPGW QP-TPGW QP-VBGW QP-VBGW QP-VBGW QP-VBGW QP-VCGW I.C.dia Thickness Hole dia Corner R CBN length : Stockeditems : Coming soon 9

Practical Examples Work piece type Grade Automotive parts 2QP-VNGA1648 SCr42,

Cutting conditions Cutting speed : Vc (m/min) Feed : f (mm/rev) Depth of cut : ap

processed 3 2 1 Doubled tool life! Excellent surface roughness.

Doubled tool life due to higher wear resistance.

parts 2QP-CNGA1248 SKH54, HS6-5-4 (63 ~ 64HRC) ø1 mm ø5 mm (mm) Machining 9 ~12 1.

10 Practical Examples Work piece type Grade Automotive parts 2QP-VNGA1648 SCr42, 2Cr4(H) (6 ~ 65HRC) Automotive parts 2QP-DNGA1544 SCM42H (58 ~ 6HRC) ø1 mm ø4 mm Cutting conditions Cutting speed : Vc (m/min) Feed : f (mm/rev) Depth of cut : ap (mm) Machining ~ Continuous cutting Continuous cutting Dry Dry Results Number of pieces processed Doubled tool life! Excellent surface roughness. Number of pieces processed Doubled tool life! Doubled tool life due to higher wear resistance. Work piece type Grade Automotive parts 2QP-CNGA1248 SCr42, 2Cr4(H) Automotive parts 2QP-CNGA1248 SKH54, HS6-5-4 (63 ~ 64HRC) ø1 mm ø5 mm Cutting conditions Cutting speed : Vc (m/min) Feed : f (mm/rev) Depth of cut : ap (mm) Machining 9 ~ ~.5.5 Continuous cutting Heavy interrupted cutting Water soluble Water soluble Results After machining 2 pcs. has normal wear and stable tool life. Number of pieces processed Chipping 14% tool life improvement! 1

Work piece type Grade Automotive parts 2QP-DNGA1548 SCr42, 2CrS4 (6 ~ 65HRC) Machine parts (Wear parts) 2QP-DNGA1544 SKH51, HS6-5-2 (64HRC) ø4

5 Continuous to interrupted cutting Continuous to interrupted cutting Dry Dry Results Number of pieces processed 15 1 5 13 times tool life!

Work piece type Grade Automotive parts 2QP-CNGA1248 SCr42H, 2Cr4(H) Truck parts 2QP-CNGA1248 SCM42 (59 ~ 63HRC) ø2 mm Cutting conditions

11 Work piece type Grade Automotive parts 2QP-DNGA1548 SCr42, 2CrS4 (6 ~ 65HRC) Machine parts (Wear parts) 2QP-DNGA1544 SKH51, HS6-5-2 (64HRC) ø4 mm 4 - ø12 mm ø1 mm Cutting conditions Cutting speed : Vc (m/min) Feed : f (mm/rev) Depth of cut : ap (mm) Machining Continuous to interrupted cutting Continuous to interrupted cutting Dry Dry Results Number of pieces processed times tool life! Fracture has 13 times longer tool life than competitors. After machining 5 pcs. is stable, even in heavy interrupted. Still available. Work piece type Grade Automotive parts 2QP-CNGA1248 SCr42H, 2Cr4(H) Truck parts 2QP-CNGA1248 SCM42 (59 ~ 63HRC) ø2 mm ø1 mm Cutting conditions Cutting speed : Vc (m/min) Feed : f (mm/rev) Depth of cut : ap (mm) Machining ~ ~.15 Continuous cutting Continuous to interrupted cutting Water soluble Dry (Air) Results Number of pieces processed Chipping Tool life tripled! No chippings. Tripled tool life, and more stable. Number of pieces processed % tool life improvement! Tool life is 18% longer than competitors with stability, even when interrupted machining. 11

Tungaloy Corporation (Head office) 11-1 Yoshima-Kogyodanchi Iwaki-city, Fukushima, 97-1144 Japan Phone: +81-246-36-851 Fax: +81-246-36-8542 http://www.tungaloy.co.jp/ Tungaloy America, Inc.

12 Tungaloy Corporation (Head office) 11-1 Yoshima-Kogyodanchi Iwaki-city, Fukushima, Japan Phone: Fax: Tungaloy America, Inc. 1226A Michael Drive, Wood Dale, IL.6191, U.S.A. Phone: Fax: Tungaloy Canada 432 Elgin St. Unit 3, Brantford, Ontario N3S 7P7, Canada Phone: Fax: Tungaloy de Mexico S.A. C Los Arellano 113, Parque Industrial Siglo XXI Aguascalientes, AGS, Mexico 229 Phone: Fax: Tungaloy do Brasil Comércio de Ferramentas de Corte Ltda. Rua dos Sabias N Vinhedo, São Paulo, Brazil Phone: Fax: Tungaloy Germany GmbH Elisabeth-Selbert-Strasse 3 D-4764 Langenfeld, Germany Phone: Fax: Tungaloy France S.A.S. 6 Avenue des Andes F Courtaboeuf Cedex, France Phone: Fax: Tungaloy Italia S.r.I. Via E. Andolfato 1 I-2126 Milano, Italy Phone: Fax: Tungaloy Czech s.r.o Turanka 115 CZ-627 Brno, Czech Republic Phone: Fax: Tungaloy Ibérica S.L. C/La Pau, nº46 E-8243 Manresa (BCN), SPAIN Phone: Fax: Tungaloy Scandinavia AB S:t Lars Väg 42A SE-2227 Lund, Sweden Phone: Fax: LLC Tungaloy Rus Grazhdanskiy Prospectus, 29a Belgorod, 3819, Russia Phone: Fax: Tungaloy Polska Sp. z o.o. ul. Genewska Warszawa, Poland Phone: Fax: Tungaloy Cutting Tool (Shanghai) Co.,Ltd. Rm No 41 No.88 Zhabei, Jiangchang No.3 Rd Shanghai 2436, China Phone: Fax: Tungaloy Cutting Tool (Thailand) Co.,Ltd. 11th Floor, Sorachai Bldg. 23/7, Soi Sukhumvit 63 Klongtonnue, Wattana, Bangkok 111, Thailand Phone: Fax: Tungaloy Singapore (Pte.), Ltd. 5 Kallang Avenue #6-3 Noel Corporate Building Singapore Phone: Fax: Tungaloy India Pvt. Ltd. 21, 2nd Floor, Krishna Apra Business Square, Netaji Subhash Place, Pitampura, Delhi , India Phone: Fax: Tungaloy Korea Co., Ltd #1312, Byucksan Digital Valley 5-cha 6-73 Gasan-dong, Geumcheon-gu Seoul, Korea Phone: Fax: Tungaloy Malaysia Sdn Bhd 5 K-2, Kelana Mall, Jalan SS6/14, Kelana Jaya, 4731 Petaling Jaya, Selangor Darul Ehsan, Malaysia Phone: Fax: Distributed by: ISO 91 certified ISO 141 certified QCJ56 EC97J1123 Tungaloy Corporation Tungaloy Group Japan site and Asian production site 18/1/ /11/1997 Produced from Recycled paper Jul. 21 (TJ)

NEW. The new standard for hardened steel machining. New coated CBN grade for hardened steel turning. Keeping the Customer First

NEW. The new standard for hardened steel machining. New coated CBN grade for hardened steel turning. Keeping the Customer First Keeping the Customer First Tungaloy Report No. 369-J 388-US New coated CBN grade for hardened steel turning NEW The new standard for hardened steel machining New coated CBN grades BXM series NEW For high