SECOMAX PCBN FOR TURNING CASE HARDENED STEEL

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1 SECOMAX PCBN FOR TURNING CASE HARDENED STEEL

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3 ANSWERING THE ISSUES FOR CASE HARDENED STEEL LIGHTER, STRONGER, TOUGHER Industry s never ending quest for new and better materials, improvements in quality, and more durable products all place increased demands on cutting tool technology and materials. Seco prides itself in innovation in tooling and processes through knowledge driven solutions and a complete program of low cbn content inserts for machining Case Hardened Steel. With six Secomax grades, including the latest coated CBN160C, this range of grades covers the spectrum of Case Hardened Steels in the HRc area. HARD TURNING vs. GRINDING: YOU WIN As our PCBN technology continues to advance, the machining envelop has swollen to consume what previously required secondary operations, namely grinding. This is due primarily to the high surface finishes possible across a broad range of lathe operations. The results are numerous and, together, amount to a significant impact on your business. Greater flexibility in your processes; lower energy costs; reduced capital equipment investment; less outsourcing; reduced tool inventories; reduced environmental effect due to drymachining; easier manufacturing processes; and increased overall productivity are all byproducts of a key change such as switching to PCBN. COMPLEMENTING THESE GRADES There are numerous choices of formats and styles, as well as wiper inserts, including two new patented twisted wiper geometries that improve productitivity and work-piece quality. Most case hardened steels are used in industries such as automotive where limited or unmanned, high volume production of parts is commonplace. The manufacture of gears, shafts, bushings, clutch sleeves and CV joints are typical examples. Similar parts made by defense, agriculture and machine tool fabricators represent other major sources of Case Hardened Steel machining. It is essential that these parts remain accurate, tough, resilient and low in cost That s where we can help most. 3

4 WHY SECOMAX? PCBN -POLYCRYSTALLINE CUBIC BORON NITRIDE.or more simply cbn, is a sintered cutting tool material formed under ultra high pressure and temperature resulting in a wear resistant composite with properties very close to diamond. Secomax is a comprehensive and expanding family of PCBN inserts formulated, and specifically developed, for the type of material being machined. We are concentrating on a range of grades in low cbn content inserts for machining Case Hardened Steel to make sure our customers can provide components to their customers that reflect the highest quality and lowest possible production costs. Our efforts have focused on expanding industry s choices for machining the various Case Hardened Steel components, says Eilert Kautto, Product Manager, PCBN, With the introduction of the coated CBN160C, for secured interrupted machining, we can offer higher durability making it possible for our customers to enjoy longer tool life, less indexing and fewer setups even with severely interrupted machining, Kautto continues. INNOVATIVE TOOLING FOR THE NEXT LEVEL OF PRODUCTIVITY Today, Seco is the only cutting tool manufacturer to offer solid PCBN inserts in the low cbn content area. This provides our customers with a significant opportunity for productivity by using the entire cutting edge length with capability for plunge turning. Additionally, it provides compared to brazed inserts, a very cost effective machining solution by offering the maximum number of cutting edges per insert. We will also continue to develop other tooling and machining processes, notes Anders Wickman, Product Specialist PCBN. Such developments include wiper inserts for high feed applications, and a range of insert geometries including Multi-Directional Turning (MDT) tooling for reduced tool changes and plunge turning. 4

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6 CBN160C: BUILT FOR HEAVY INTERRUPTIONS AND SPEED A SOPHISTICATED, YET SIMPLIFIED RANGE OF LOW-CONTENT PCBN Not all Case Hardened Steel is the same. Although it has been with us since the beginning of the Industrial Revolution, depth and hardness vary according to part specifications. There are six members in the low cbn content family, three coated and three uncoated, designed to meet the requirements of various applications and operations, such as work piece shapes, interruptions and severity of machining. LOWER PRODUCTION COSTS WITH CBN160C CBN160C has been designed, developed and tested to fill industry s ever increasing demands for lower production costs. Our unique (Ti,Si)N coating, designated C, significantly improves wear resistance, increases tool life and enables higher speeds and feeds. Our process provides a crack-resistant coating and grain structure with a low coefficient of friction and sharper cutting edges. This coating is bonded to a specific balance between substrate (cbn content, grain size, binder) and edge micro geometry making this grade very well suited to heavy interrupted and high speed machining. CBN160C A NEW INDUSTRY STANDARD The predominant failure conditions of PCBN cutting tool inserts, when used in interrupted machining, is thermal cracking, followed by erosion around the cracks and eventual edge chipping. CBN160C is highly resistant to thermal cracking and thus premature failure or shortened life. Our results show that parts per edge are more than doubled compared to competition in applications such as facing pinion gears; facing and ID turning of ring gears; good examples of heavy interrupted cutting. This grade in combination with our (Ti,Si)N coating is specifically developed for dry machining pre-hardened steels, such as Case Hardened Steel in the 45 to 65 HRc range. We look for CBN160C to become an industry standard. 6

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8 GRADES AND FORMATS COATED UNCOATED CBN050C PVD coated with (Ti,Si)N for durability and wear indication Brazed, full face and solid formats New Helix wiper geometries available High feed / High speed and plunging High speed continuous machining Good light interupted cut performance CBN10 Brazed and full face formats Continuous and light interrupted cuts Threading, grooving and groove turning CBN160C PVD coated with (Ti,Si)N for durability and wear indication Brazed and full face formats Withstands severe interruptions High feed / High speed Solid formats Continuous and light interrupted cuts Plunging Crossbill wiper geometry P PVD coated with Ti(Al)+TiN Solid formats Continuous and light interrupted cuts CBN150 Brazed and full face formats Preferred for interrupted cuts 8

9 CHOICES TO PLEASE BOTH OPERATOR AND ACCOUNTANT FORMATS FOR MAX EFFICIENCY A complete variety of formats is available to suit both your application and your budget. Coated and uncoated grades are available in single brazedtipped formats for continuous and interrupted turning and offer users a lower insert investment. Also, multiple brazed corner inserts provide the same performance as single tip inserts, but with reduce cost per edge and quicker indexing to the next corner to maximize your machine uptime. Seco offers full face PCBN with full length cutting edges for e.g. plunging operations. Included are versions with C-lock for rigidity in processes where less than optimal set ups are common. Full face is available in several grades to match the need for increasing speeds. They are also easy to index. Solids and solids with pin lock hole for rigidity are also available in several grades which are ideal for plunge turning and are the most cost effective inserts for high production, achieving the maximum number of cutting edges per insert. STYLES WELL-SUITED FOR YOUR PLANT FLOOR Along with the several formats, this new family comes in all the normally used styles, including Square, Triangle, the three Diamonds C 80, V 35 and D 55 - as well as Trigon (W), round and a range of inserts for our unique MDT system. FORMATS BRAZED FULL FACE SOLID Single tipped Economical choice for lower parts volumes Stable set up Available in grades CBN10 and CBN050C Full face Full length cutting edge for plunging Available in grades CBN10, CBN050C, CBN150 and CBN160C Solid Plunge Turning Most cost effective for high production Available in grades CBN050C and Multi Corner Economical choice for moderate parts volumes Ease of set up and indexing Available in grades CBN10, CBN050C, CBN150 and CBN160C Full face / C-lock Rigidity in process Multiple cutting edges Positive geometries for reduced cutting forces Standard toolholders can be used Available in grade CBN10 Solid with hole Rigid set up required Available in grades CBN050C and MDT Multi Directional Turning Complex part profile, single tool multitask Available in grade CBN10 9

10 HIGH FEED MACHINING Many factors influence surface finish, however, the two most important ones are feed rate and the size of the corner radius. The introduction of the new Helix wiper technology has increased our ability to turn up the feed rates while maintaining a superior finish. Reduced machining time is the name of the game in keeping production costs lower. Seco wiper inserts combine the high feed capacity and high quality surface finish given by larger round inserts and the low cutting forces and flexibility permitted by pointed inserts. By combining the high speed capabilities of grades such as CBN050C, with wiper geometries, you have the potential to increase cutting speed and feed rates that contribute significantly to the goals of reduced cycle times and high productivity machining. 10

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12 THE HELIX WIPER TECHNOLOGY Our unique patented, Helix wiper concept is designed for optimization in finish machining. It has a wiper on both sides of the corner radii (as the standard) but the protection chamfer is twisted from negative to positive or from positive to negative depending on the application. It is available in grade CBN050C. The following considerations apply when selecting the appropriate geometry: POSITIVE WIPER, WZP Reducing vibrations in weak setups Lower radial cutting forces Used where standard wiper cannot be used NEGATIVE WIPER, WZN Longer tool life Reducing vibrations in stable setups Increasing compressive stresses Big angle Small angle Small angle Big angle Wiper section Wiper section Helix Positive Wiper Helix Negative Wiper Std. Wiper Competitor PCBN Tool life (parts/edge) Tool life (parts/edge) 12

13 CROSSBILL WIPER Crossbill is available in grade in both right and left handed geometry designs. It offers great flexibility in that it can machine all the way to a shoulder, making it possible to machine a perfect radius with no deviation from the component s normal corner radius shape. This wiper also has a standard chamfer (0.10mm x 20 deg) and is used in general machining operations. Wiper segment Right hand version Wiper segment STANDARD WIPERS The standard wiper geometry has wiper edges on both sides of the corner radii, in a standard chamfer 0.1mm x 20 deg. It is used in general applications, machining in two directions with full wiper effectiveness, e.g. OD/ID turning and facing. It is available in grades CBN10, CBN050C, and CBN160C. 13

14 PLUNGING - A NEW APPROACH TO MODERN MACHNING Because the pressure is so heavy for our customers to reduce cycle times, we decided to take the plunge. Plunge turning, that is. Accomplished with solid and full face inserts such as CBN050C, and CBN10. With plunge turning, production costs are significantly reduced through shorter machining time (as much as 90% shorter). The results are a dramatic increase in the number of machined surfaces per cutting edge. Studies have shown PCBN, when used in plunge turning processes, can be 10 to 300 times more effective in terms of overall productivity when compared to conventional turning methods. And, plunge turned parts exhibit lower residual stresses with the sealing properties equal to or better than ground surfaces. T-STYLE PLUNGING A breakthrough has been achieved in plunge turning with Secomax and CBN050C. Using solid triangular, T style, PCBN inserts with superior cutting edges and good rigidity, the two great advantages of plunge turning, i.e., reduced cutting time (as much as 90%) and improved surface integrity can be achieved. Plunge turning also lowers residual stress in the axial direction, distributing it in the tangential direction instead, which is a benefit when compared to a ground surface. All of this translates into longer tool life, lower production costs and higher workpiece quality money saving solutions from Seco. MULTI DIRECTIONAL TURNING (MDT) A combination that is hard to beat grinding quality and toolholder stability both from Seco Tools. Multi Directional Turning (MDT) is an innovative technique where a single tool can be used for multiple processes. Almost anything in machining is possible with Secomax MDT: side turning, face turning, internal machining; plunging, grooving and even parting-off. MDT is really a system made up of a unique PCBN insert mated to its own toolholder by a patented series of serrations called Secoloc. Commonly used insert styles meeting ISO standards are not always suitable for machining grooves, so in order to machine all surfaces, groove turning inserts are necessary. MDT not only eliminates the need for separate inserts but it also provides the accuracy in positioning and the rigidity required in grooving, turning in both directions and for plunging as well. The edge quality and selected Secomax PCBN grades guarantee excellent surface finish and long tool life. 14

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16 TEST RESULTS PINION GEAR SHAFT Material DIN 16MnCrS5 Surface Pre-machined Operation Facing; D 60 Grade CBN160C Insert DNGA150608S L1-B Toolholder C5-DCLNL Cutting data v c 140 m/min f z 0,14 mm/rev a p 0,30/0,15/0,01 (3 cuts) Coolant No Tool life Competitor performs 80 parts/edge Cutting time: 0,27 min/part; cutting length: 40mm/part Tool life CBN 160C ~ 160 parts RING GEAR Material DIN 16MnCrS5 Surface Pre-machined Operation ID turning; D125 Grade CBN160C Insert CNGA120412S L1-B Toolholder C5-DCLNL Facing / ID turning Cutting data v c 95 m/min / 160 m/min f z 0,25 mm / 0,23 mm a p 0,20 / 0,20 Coolant No Tool life Competitor performs 130 parts/edge, Cutting time (facing): 0,40 min/part; Cutting length: 20 mm/ part, Cutting time (ID turng): 0.40 min/part; Cutting length: 20 mm/ part Tool life CBN160C ~ 230 parts/edge CBN160C CBN160C Competitor Competitor Tool life (parts/edge) Tool life (parts/edge) CLUTCH CYLINDER Material Case hardened steel Surface 55 to 60 HRc Operation OD Continues cut Grade CBN050C Insert CNGA120408S-L1-WZP (Wiper) Toolholder Special Cutting data v c 200 m/min f z 0,08 mm/rev (std wiper) 0,20 mm/rev (sharp wiper) a p 0,15 mm Coolant yes Tool life 2,5 times faster and more than double tool life Helix Positive Wiper PINION GEAR SHAFT Material DIN 16 MnCr5 Surface Pre-machined, hardened to 60 HRc Operation OD turning / facing Grade CBN050C Insert DNGA150612S -L1-WZN (Wiper) Toolholder Special Cutting data v c 160 m/min f z 0,25 mm/rev a p 0,15 mm Coolant No Tool life 6 times higher tool life compared to the competitor. Helix Negative Wiper Std. Wiper Competitor PCBN Tool life (parts/edge) Tool life (parts/edge) 16

17 TEST RESULTS GEAR SHAFT Material Case hardened steel Surface 58 HRc Forged Operation Continuous turning Grade CBN050C Insert TNGX110304S-WZ (Wiper) Toolholder Special Cutting data v c 200 m/min f z 0,3 mm/rev a p 0,1 mm Coolant No Tool life Cycle time reduced by 50% compared to grinding. Machined in one set up. CONSTANT VELOCITY JOINT Material Case hardened steel Surface 60 HRc Forged Operation Turning Grade Insert TNGX110308S-WZ (Wiper) Toolholder Special Cutting data v c 180 m/min f z 0,15 mm/rev a p 0,15 mm Coolant No Tool life = Wiper geometry improves productivity. Cycle time reduced by 40 50% compared with grinding. Grinding Grinding CBN050C wiper wiper Machining time (%) Cycle time (%) SYNCROMESH GEARS Material Case hardened steel Surface 60 HRc Forged Operation Plunging the taper Grade Insert TNGN110304E Toolholder Special Cutting data v c 200 m/min f z 0,04 mm/rev a p 0,15 mm Coolant No Tool life, plunging = 0,18 sec. machining time. Comp. PCBN Conventional = 6,9 sec. machining time. GEAR WHEELS Material Case hardened steel Surface HRc Forged 1,5 microns Rz Operation Boring Grade CBN050C Insert TNGX110304S-WZ (Wiper) Toolholder Special Cutting data v c 215 m/min f z 0,15 mm/rev a p 0,05 mm Coolant No Tool life CBN Wiper = 0,15 mm/rev Comp. PCBN Conventional = 0,05 mm/rev. Same tool life and surface finish. Productivity improved with CBN050C wiper. Comp. PCBN Conventional CBN050C Wiper Comp. PCBN Conventional plunging Machining time (sec.) Feed rate (mm/rev) 17

18 TEST RESULTS GEAR SHAFT Material Case hardened steel Surface HRc Forged (smooth) Operation OD Turning Continuous cutting Grade Insert TNGN110308S Toolholder Special Cutting data v c 150 m/min f z 0,1 mm/rev a p 0,1 0,15 mm Coolant No Tool life = 110 minutes Comp. PCBN = 63 minutes PINION GEAR Material Case hardened steel Surface 60 HRc Forged (smooth) Operation OD Turning - Continuous/spline Grade CBN10 Insert TNGN110308S-LF Toolholder Special Cutting data v c 180 m/min f z 0,1 mm/rev a p 0,2 0,3 mm Coolant No Tool life Surface finish required 0,8 microns Ra CBN10 Comp. PCBN Tool life/edge (min) Tool life/ No. of parts/edge GEAR SHAFT Material Case hardened steel Surface HRc Forged (smooth) Operation OD Turning the spline Interrupted Grade CBN150 Insert TNGN110308S-LF Toolholder Special Cutting data v c 140 m/min f z 0,1 mm/rev a p 0,1 0,15 mm Coolant No Tool life CBN 150 = 100 minutes Comp. PCBN = 77 minutes CLUTCH SLEEVES Material Case hardened steel Surface 58 HRc Forged Operation Plunging of two inner faces + the inner diameter Grade CBN10 Insert LCGN E-LF (spec) Toolholder Special Cutting data v c 160 m/min f z 0,04 mm/rev a p 0,05 0,1 mm Coolant No Tool life ~ 500 parts/edge CBN150 CBN10 Comp. PCBN Tool life/edge (min) Tool life/ No. of parts/edge 18

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20 CODE KEY Insert shape Tolerances Cutting edge length Nose radius Direction of cutting Internal designation C C G W 09 T3 04 S - - L0 - WZ Side clearance angle Insert type Thickness Cutting edge designation Manufacturer option INSERT PROGRAMME, CBN CASE HARDENED Uncoated Grades Coated Uncoated Grades Coated Inserts Part No. CBN10 CBN150 CBN050C CBN160C P Inserts Part No. CBN10 CBN150 CBN050C CBN160C P CCGW 09T308S-L0-B CCGW S-L S-L0 CCGW E-L1-B CCGW S L1-B S L1-B CCGW 09T304E-L1-B CCMW E-L E-L0 CCMW S-L S-L0 CCMW 09T304E-L0 09T308E-L0 CCMW 09T304E-L0-B 09T308E-L0-B CCGW 09T304S L1-B 09T308S L1-B 09T312S L1-B CCMW 09T304S-L0 09T308S-L0 09T312S-L0 CCGW 09T308E-L1-B CCGW 09T304E-L0-WZ CCMW 09T304S-L0-B 09T308S-L0-B CCGW 09T304S-L0-WZ CCGW 09T304S L1-WZ-B CCGW S LF S LF S LF CCGW 09T302S LF 09T304S LF 09T308S LF CNGA S-L S-L S-L0 CNGA S-L0-B S-L0-B S L0-B S-L0-B S L0-B CNGA S-L S L1-B S-L S L1-B S-L S L1-B CNGA S-L1-WZ S L1-WZ-B S L1-WZ-B CNGA S-L1-WZN-B S-L1-WZP-B 20

21 Uncoated Grades Coated Uncoated Grades Coated Inserts Part No. CBN10 CBN150 CBN050C CBN160C P Inserts Part No. CBN10 CBN150 CBN050C CBN160C P CNGN S S S RCGN 0803M0S-LF 0803M0S LF CNGN 09304S-WZ RCGS 6.35S-LF DCGW E-L1-B DCGW S L1-B S L1-B S L1-B DCGW 11T304E-L1-B DCGW 11T304S L1-B 11T308S L1-B 11T312S L1-B RNGN S-LF S LF RNGN S-LF S LF RNGN E DCMW E-L0-B E-L0-B RNGN S S DCMW S-L0-B S-L0-B S-L0-B DCMW 11T302S-L0 11T304S-L0 11T308S-L0 RNGN E E25 RNGN S S RNGN S DCMW 11T304E-L0-B 11T308E-L0-B DCMW 11T304S-L0-B 11T308S-L0-B SNGA S L1-D DNGA S-L0-B S L0-B S-L0-B S L0-B DNGA S-L S-L0 SNGN S S SNGN S S S S DNGA S-L0-B S-L0-B S L0-B TCGN E-LF DNGA S-L S-L S-L1 DNGA S L1-B S L1-B S L1-B DNGA S L1-B S L1-B S L1-B TCGW E-L E-L1-C TCGW S L S L1-C TCGW S L1-C S L1 DNGN E25 TCGW S LF S LF DNGN S S TCGW S LF S LF 21

22 Uncoated Grades Coated Uncoated Grades Coated Inserts Part No. CBN10 CBN150 CBN050C CBN160C P Inserts Part No. CBN10 CBN150 CBN050C CBN160C P TCMW E-LO E-LO TCMW E-LO-C E-LO-C TPGN E TPGN S S TCMW S-LO S-LO VBGW S-L0 TCMW S-LO-C S-LO-C VBGW S-L0-B S L0-B S-L0-B S L0-B TNGA S-LO S-LO TNGA S-LO-C S-LO-C S LO-C TNGA S-L S L S-L S-L L1 TNGA S L1-C S L1-C S L1-C VBGW E-L1-B E-L1-B E-L1-B E L1-B VBGW S L1-B S L1-B S L1-B VBGW E-L2 VBGW S-L S-L2 TNGA S S TNGA S-WZ VNGA S-L S-L S-L0 VNGA S-L0-B S L0-B S-L0-B S L0-B TNGN S LF S LF VNGA S L1-B S L1-B S L1-B TNGN E E E E25 TNGN S S S S S S TNGN S VNGA S-L S-L2 WNGA S-L0-C S-L0-C WNGA S L1-C WNGA S-L0-WZ-C WNGA S L1-WZ-C S L1-WZ-C TNGX S-WZ S WZ S WZ S-WZ TNGX S-R-WZ TNGX S-L-WZ WNGA S S S S S S WNGA S-WZ S WZ 22

23 Uncoated Grades Coated Uncoated Grades Coated Inserts Part No. CBN10 CBN150 CBN050C CBN160C P Inserts Part No. CBN10 CBN150 CBN050C CBN160C P LCGN E-LF S-LF LCGN 1603M0-0300E-LF 1603M0-0300E25-LF LCGN E-LF S-LF LCGN 1603M0-0300S-LF LCGN 1604M0-0400E25-LF LCGN 1303M0-0300E-LF 1303M0-0300S-LF LCGN 1604M0-0400S-LF LCGN 1605M0-0500E25-LF LCGN 1304M0-0400E-LF 1304M0-0400S-LF LCGN 1605M0-0500S-LF LCGN 1606M0-0600E25-LF LCGN E-LF E25-LF LCGN 1606M0-0600S-LF LCGN S-LF LCGN E-LF E25-LF LCGN S-LF LCGN E-LF E25-LF LCGN S-LF LCGN E-LF E25-LF LCGN S-LF 23

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