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

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Hillary Wade
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1 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

2 New coated CBN grades BXM series NEW For high speed machining NEW All-round BXM1 Excellent crater wear resistance! Continuous cutting Newly developed CBN substrate for high speed cutting! Standard cutting condition Application Grades Machining Mode Cutting Speed Vc (SFM) ap(in) f(ipr) Hard Materials BXM1 Continuous interrupted Continuous Interrupted

Applicable for all types of hardened steel turning 99 66 33 BXM1 Continuous Continuous cutting New

has normal wear pattern without peeling Normal wear Insert Cutting speed Coolant Peeling : 2QP-CNGA 432

6" : Water soluble Competitor Tool life (competitor: 1) Cutting performance 6 5 4 3 2 1 Competitor 5

3 Applicable for all types of hardened steel turning BXM1 Continuous Continuous cutting New coating layer Interrupted cutting Remarkable adhesion strength Unique CBN substrate High chipping resistance!! Extremely tough Substrate!! Application range Cutting speed Vc (SFM) Interrupted Hard Materials Heavy Comparison of damage BMX2 has normal wear pattern without peeling Normal wear Insert Cutting speed Coolant Peeling : 2QP-CNGA 432 : SCM415H (6HRC) : Vc = 43 SFM : f =.6 ipr : ap =.6" : Water soluble Competitor Tool life (competitor: 1) Cutting performance Competitor 5 times longer tool life! Interrupted cutting Removing carburized layer Continuous cutting Vc = 43 SFM f =.6 ipr ap =.6 in Vc = 36 SFM f =.5 ipr ap =.24 in Vc = 43 SFM f =.6 ipr ap =.6 in Insert Coolant : 2QP-CNGA 432 : SCM415H : Water soluble 3

Cutting performance BXM1 High speed machining comparisons (Vc = 98 SFM) Max. flank wear width: VBmax (in).6.

2 Competitor Conventional BXM1 1 2 3 4 5 6 Cutting time: T (min) Insert Cutting speed Work process Coolant :

1 in : Continuous cutting : Dry Continuous cutting Comparison of wear resistance Continuous cutting Max.

2 Competitor Conventional 2 4 6 8 1 Cutting time: T (min) Insert Cutting speed Work process Coolant : 2QP-CNGA 432 :

4 Cutting performance BXM1 High speed machining comparisons (Vc = 98 SFM) Max. flank wear width: VBmax (in).6.4 Chipping Chipping.2 Competitor Conventional BXM Cutting time: T (min) Insert Cutting speed Work process Coolant : 2QP-CNGA 432 : SCM415H (59 ~ 61HRC) : Vc = 98SFM : f =.4 ipr : ap =.1 in : Continuous cutting : Dry Continuous cutting Comparison of wear resistance Continuous cutting Max. flank wear width: VBmax (in) Competitor Conventional Cutting time: T (min) Insert Cutting speed Work process Coolant : 2QP-CNGA 432 : SCM415H (59 ~ 61HRC) : Vc = 43SFM : f =.6 ipr : ap =.6 in : Continuous cutting : Water soluble Comparison of toughness After 19 minutes After 19 minutes interrupted cutting Cutting time: T (min) Competitor Insert Cutting speed Work process Coolant : 2QP-CNGA 432 : SCM415H (59 ~ 61HRC) : Vc = 43 SFM : f =.6 ipr : ap =.6 in : interrupted cutting : Water soluble 4

Hard Breakers for removing the carburized layer from case hardened shafts.

HF type For finishing Example of chips Single sided CBN insert provides higher stability in heavy machining. Excellent chip control in small D.O.C. due to the high functional nose.

8 : f (ipr) HM type For medium cutting Example of chips Single sided CBN insert provides higher stability in heavy machining.

5 Hard Breakers for removing the carburized layer from case hardened shafts. 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 D.O.C. due to the high functional nose. Delivers exceptional surface finishes. : ap (in) HF Chipbreaker : f (ipr) HM type For medium cutting Example of chips Single sided CBN insert provides higher stability in heavy machining. Providing ideal chip control in large D.O.C due to the well designed chipbreaker. Suitable for medium cutting or roughing. : ap (in) HF Chipbreaker : f (ipr) Standard cutting condition (for removing the carburized layer) Application Grades Machining Mode Cutting Speed Vc (SFM) ap(in) f(ipr) Hard Materials HF HM

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.12 ipr 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 Insert Cutting speed Coolant : 2QP-CNGA 432 WL : SCM415 (62HRC) : Vc = 49 SFM : f =.4 ipr : ap =.6 in : 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 highly rigid toolholder like the A-Style toolholder is recommended. In the table below, recommended toolholders are shown. End cutting angle End cutting angle, recommended toolholders 2QP-CNGA 432 WL 3QP-WNGA 432 WL 2QP-DNGA 432 WJ 3QP-TNGA 332 WG End cutting angle External toolholder Internal toolholder ACLNR/L164-A AWLNR/L164-A ADJNR/L164-A DCLNR/L164 DWLNR/L164 DDJNR/L164 ATGNR/L163-A ATFNR/L163-A DTGNR/L163 DTFNR/L163 A***-ACLNR/L4-D*** A***-AWLNR/L4-D*** A***-ADUNR/L4-D*** A***-ATFNR/L3-D*** 6

7 Designation System 2 QP - CNGA Number of edges 2 Type 3 ISO symbols T-CBN (Based on ANSI standard) QP 2 One side TAC insert multi-corner 3 type Honing specification Standard :.5 in 25 +R- -L :.5 in 15 +R- -H :.5 in 35 +R- 4 Additional symbol Without Standard -L for low cutting force -H Heavy for toughness WG Wiper edge, 91 end cutting angle WJ Wiper edge, 93 end cutting angle WL Wiper edge, 95 end cutting angle 4 Chipbreaker symbol -HF -HM For finishing WL 4 For medium cutting to roughing Smaller angle makes the edge sharper with lower cutting forces. Larger angle makes the edge tougher. 7

8 8 Inserts (Negative type) Features Shape Cat. No. Grades Dimensions (in) No. of corners I.C.dia Thickness Hole dia Corner R CBN Length BXM1 ød s ød1 rε a 2QP-CNGA Standard 2QP-CNGA QP-CNGA QP-CNGA 431-L QP-CNGA 432-L QP-CNGA 433-L QP-CNGA 431-H.16.9 Heavy 2QP-CNGA 432-H QP-CNGA 433-H QP-CNGA 431WL.16.9 Wiper edge 2QP-CNGA 432WL QP-CNGA 433WL QP-DNGA QP-DNGA Standard 2QP-DNGA QP-DNGA 441 s QP-DNGA 442 s QP-DNGA 443 s QP-DNGA 431-L QP-DNGA 432-L QP-DNGA 433-L QP-DNGA 431-H Heavy 2QP-DNGA 432-H QP-DNGA 433-H Wiper edge 2QP-DNGA 431WJ QP-DNGA 432WJ QP-SNGA Standard 2QP-SNGA QP-SNGA QP-SNGA 432-L QP-SNGA 433-L Heavy 2QP-SNGA 432-H QP-SNGA 433-H QP-TNGA Standard 3QP-TNGA QP-TNGA QP-TNGA 331-L QP-TNGA 332-L QP-TNGA 333-L QP-TNGA 331-H Heavy 3QP-TNGA 332-H QP-TNGA 333-H Wiper edge 3QP-TNGA 331WG s QP-TNGA 332WG s QP-VNGA Standard 2QP-VNGA QP-VNGA QP-VNGA 331-L QP-VNGA 332-L Heavy 2QP-VNGA 331-H QP-VNGA 332-H Standard 3QP-WNGA Wiper edge 3QP-WNGA 432WL l : Stocked items s : Japan Stocked

9 Inserts (Negative type with chipbreaker) Features Shape Cat. No. With chipbreaker Grades BXM1 No. of corners I.C.dia ød Thickness s Dimensions (in) Hole dia ød1 Corner R rε CBN Length a 2QP-CNGM 432-HF QP-CNGM 433-HF QP-DNGM 432-HF QP-DNGM 433-HF QP-TNGM 332-HF QP-TNGM 333-HF QP-VNGM 332-HF With chipbreaker 2QP-CNGM 432-HM QP-CNGM 433-HM QP-DNGM 432-HM QP-DNGM 433-HM QP-TNGM 332-HM QP-TNGM 333-HM QP-VNGM 332-HM Inserts (Positive type) Features Shape Cat. No. Standard Grades BXM1 No. of corners I.C.dia ød Dimensions (in) Thickness s Hole diacorner R ød1 rε CBN Length a ød 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 l : Stocked items 9

Practical Examples Work piece type Automotive parts Automotive parts Insert 2QP-VNGA 431 2QP-DNGA 431 Grade BXM1 BXM1 SCr42, 2Cr4(H) (6 ~ 65HRC) SCM42H (58 ~ 6HRC) ø3.94 in ø1.

: f (ipr).3.4 : ap (in).6.8 Machining Continuous cutting Continuous cutting Coolant Dry Dry Results Number of pieces processed 3 2 1 BXM1 Competitor Excellent surface roughness.

10 Practical Examples Work piece type Automotive parts Automotive parts Insert 2QP-VNGA 431 2QP-DNGA 431 Grade BXM1 BXM1 SCr42, 2Cr4(H) (6 ~ 65HRC) SCM42H (58 ~ 6HRC) ø3.94 in ø1.57in Cutting conditions Cutting speed: Vc (SFM) : f (ipr).3.4 : ap (in).6.8 Machining Continuous cutting Continuous cutting Coolant Dry Dry Results Number of pieces processed BXM1 Competitor Excellent surface roughness. Work piece type Automotive parts Automotive parts Insert 2QP-CNGA 432 2QP-CNGA 432 Grade SCr42, 2Cr4(H) Doubled tool life! Number of pieces processed Doubled tool life! BXM1 Competitor Doubled tool life due to higher wear resistance. SKH54, HS6-5-4 (63 ~ 64HRC) ø3.94 in ø1.97 in Cutting conditions Cutting speed: Vc (SFM) : f (ipr).5.4 : ap (in).12.2 Machining Continuous cutting Heavy interrupted cutting Coolant Water soluble Water soluble Results After machining 2 pcs. Competitor has normal wear and stable tool life. Number of pieces processed 15 1 Chipping 5 Competitor 14% tool life improvement! 1

Work piece type Automotive parts Machine parts (wear parts) Insert 2QP-DNGA 432 2QP-DNGA 431 Grade SCr42, 2CrS4 (6 ~ 65HRC) SKH51, HS6-5-2 (64HRC) ø1.57 in 4 - ø.472 in ø3.

11 Work piece type Automotive parts Machine parts (wear parts) Insert 2QP-DNGA 432 2QP-DNGA 431 Grade SCr42, 2CrS4 (6 ~ 65HRC) SKH51, HS6-5-2 (64HRC) ø1.57 in 4 - ø.472 in ø3.94 in Cutting conditions Cutting speed: Vc (SFM) : f (ipr).3.3 : ap (in).4.2 Machining Continuous to interrupted cutting Continuous to interrupted cutting Coolant Dry Dry Results Number of pieces processed Competitor has 13 times longer tool life than competitors. Work piece type Automotive parts Truck parts Insert 2QP-CNGA 432 2QP-CNGA 432 Grade SCr42H, 2Cr4(H) 13 times tool life! Fracture After machining 5 pcs. Competitor is stable, even in heavily interrupted cuts. SCM42 (59 ~ 63HRC) ø.787 in ø3.94 in Cutting conditions Cutting speed: Vc (SFM) : f (ipr).6.5 : ap (in).8.4 Machining Continuous cutting Continuous to interrupted cutting Coolant Water soluble Dry (Air) Results Number of pieces processed Chipping Tool life tripled! Competitor No chipping. Tripled the tool life, and was more stable. Number of pieces processed % tool life improvement! Competitor Tool life is 18% longer than competitors with stability, even when interrupted machining. 11

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12 Tungaloy America, Inc N. Ventura Dr. Arlington Heights, IL 64 Inside Sales : Technical Support: Fax: Become a fan on facebook Follow us on Watch our videos on You Tube Tungaloy Canada 432 Elgin Street, Unit 3, Brantford, Ontario, Canada N3S-7P7 Phone: , Fax: Tungaloy de Mexico S.A. C Los Arellano 113, Vista Alegre, Aguascalientes, AGS, Mexico 229 Phone: , Fax: Distributed By: Nov. 212 (TA)

Coated CBN grade with a whole new level of cutting performance for hardened steel

TurnLine www.tungaloy.com Tungaloy Report No. 511-US Coated CBN grade with a whole new level of cutting performance for hardened steel ACCELERATED MACHINING TurnLine Remarkably long tool life in hardened