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Metallurgy 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. 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.
Machinability Overview
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. 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.
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
High-Nickel Austenitic Cast Irons A436 A439 571 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
32
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
33
34
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
35
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 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
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.
hardness HB
ASTM 48
ASTM A126
ASTM A319
ASTM A436
F10001 F10002 F10003 F10004 F10005 F10006 F10007 F10008 F11401 F11501 F11701 F12101 F12102 F12401 F12801 F12802 F12803 F13101 F13102 F13501 F13502 F13801 F13802 F14101 F14102 F14801 F15501
generally below MPa 207 (30 ksi) at or above 207 MPa (30 ksi) generally at or above 276 MPa (40 ksi) 124 MPa (18 ksi) min. 173 MPa (25 ksi) min. 207 MPa (30 ksi) min. 241 MPa (35 ksi) min. 276 MPa (40 ksi) min. 138 MPa (20 ksi) min. 145 MPa (21 ksi) min. 172 MPa (25 ksi) min. 207 MPa (30 ksi) min. 214 MPa (31 ksi) min. 241 MPa (35 ksi) min. 276 MPa (40 ksi) min. 283 MPa (41 ksi) min. 276 MPa (40 ksi) min. 310 MPa (45 ksi) min. 310 MPa (45 ksi) min. 345 MPa (50 ksi) min. 345 MPa (50 ksi) min. 379 MPa (55 ksi) min. 379 MPa (55 ksi) min. 414 MPa (60 ksi) min. 414 MPa (60 ksi) min. 483 MPa (70 ksi) min. 552 MPa (80 ksi) min. 172 MPa (25 ksi) min. 207 MPa (30 ksi) min. 172 MPa (25 ksi) min. 207 MPa (30 ksi) min. 172 MPa (25 ksi) min. 172 MPa (25 ksi) min. 138 MPa (20 ksi) min. 172 MPa (25 ksi) min.
187 max 170-229 187-241 207-255 217-269 156 156 174 210 210 212 235 235 235 250 250 265 265 282 282 302 302 131-183 149-212 118-174 171-248 118-159 149-212 99-124 124-174 Grade, Type or Number 60 (A-C) 60 70 80 55 (A-C) 55 50 (A-C) 50 45 (A-C) 45 35 (A-C) 40 (A-C) Class C 40 25 (A-C) 30 (A-C) Class B 35 20 (A-C) Class A 25 30 G1800 G2500 G3000 G3500 G4000 20
Gray, Austenitic
1 1b 2 2b 3 4 5 6
37
hardness HB
ASTM A47
ASTM A220
345 MPa (50 ksi) min. 447.9 MPa (65 ksi) min. 516.5 MPa (75 ksi) min. 516.5 MPa (75 ksi) min. 620.3 MPa (90 ksi) min. 723.2 MPa (105 ksi) min. 345 MPa (50 ksi) min. 365 MPa (53 ksi) min. 414 MPa (60 ksi) min. 448 MPa (65 ksi) min. 448 MPa (65 ksi) min. 483 MPa (70 ksi) min. 483 MPa (70 ksi) min. 586 MPa (80 ksi) min. 655 MPa (95 ksi) min. 724 MPa (105 ksi) min.
220.5 MPa (32 ksi) min. 309.7 MPa (45 ksi) min. 345 MPa (50 ksi) min. 379.3 MPa (55 ksi) min. 482.2 MPa (70 ksi) min. 586 MPa (85 ksi) min. 224 MPa (32 ksi) min. 241 MPa (35 ksi) min. 276 MPa (40 ksi) min. 310 MPa (45 ksi) min. 310 MPa (45 ksi) min.; elongation 6% min. 345 MPa (50 ksi) min. 345 MPa (50 ksi) min. 483 MPa (70 ksi) min. 552 MPa (80 ksi) min. 621 MPa (90 ksi) min.
156 max. 163-217 187-241 187-241 229-269 269-302 156 max. 156 max 149-197 156-197 156-207 179-229 196-241 217-269 241-285 269-321 32510 35018 40010 45008 45006 50005 60004 70003 80002 90001
hardness HB
ASTM A439
ASTM A571
AMS
SAE J434
MIL-I24137
as required 414 MPa (60 ksi) min. 448 MPa (65 ksi) min. 414 MPa (60 ksi) min. 552 MPa (80 ksi) min. 552 MPa (80 ksi) min. 689 MPa (100 ksi) min. 827 MPa (120 ksi) min. 400 MPa (58 ksi) min. 400 MPa (58 ksi) min. 400 MPa (58 ksi) min. 379 MPa (55 ksi) min. 379 MPa (55 ksi) min. 414 MPa (60 ksi) min. 379 MPa (55 ksi) min. 379 MPa (55 ksi) min. 448 MPa (65 ksi) min. 379 MPa (50 ksi) min. 345 MPa (50 ksi) min. 276 MPa (40 ksi) min. 310 MPa (45 ksi) min. 310 MPa (45 ksi) min. 379 MPa (55 ksi) min. 414 MPa (60 ksi) min. 483 MPa (70 ksi) min. 621 MPa (90 ksi) min. 207 MPa (30 ksi) min. 207 MPa (30 ksi) min. 193 MPa (28 ksi) min. 207 MPa (30 ksi) min. 207 MPa (30 ksi) min. 207 MPa (30 ksi) min. 207 MPa (30 ksi) min. 207 MPa (30 ksi) min. 207 MPa (30 ksi) min. 207 MPa (30 ksi) min. 172 MPa (25 ksi) min.
as reqd 170 max. 60-40-18 156-217 190 187-255 163 80-55-06 80-60-03 5316 65-45-12 5315
241-302 100-70-03 270-350 120-90-02 139-202 148-211 121-171 139-202 131-193 202-273 131-185 139-193 121-171 Grade, Type, or Number D-2 D-2B D-2C D-3 D-3A D-4 D-5 D-5B D-2M-1, D-2M-2
D7003
Ductile, Austenitic
F43000 F43001 F43002 F43003 F43004 F43005 F43006 F43007 F43010 F43020 F43021
(B) (C)
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ASTM A897-90 125-80-10 150-100-7 175-125-4 200-155-1 230-185 Grade, Type, or Number
850 MPa (125 ksi) min. 1050 MPa (150 ksi) min. 1200 MPa (175 ksi) min. 1400 MPa (200 ksi) min. 1600 MPa (230 ksi) min.
550 MPa (80 ksi) min./elongation 10% 700 MPa (100 ksi) min./elongation 7% 850 MPa (125 ksi) min./elongation 4% 1100 MPa (155 ksi) min./elongation 1% 1300 MPa (185 ksi) min.
ASTM A842 250 300 350 400 450 Grade, Type, or Number
250 MPa min. 300 MPa min. 350 MPa min. 400 MPa min. 450 MPa min.
175 MPa min./elongation 3% 210 MPa min./elongation 1.5% 245 MPa min./elongation 1.0% 280 MPa min./elongation 1.0% 315 MPa min./elongation 1.0%
ASTM A532 (class) (I) A, Ni hard (I) B, Ni hard (I) C, Ni hard (I) D, Ni hard (II) A, white iron (II) B, white iron (II) C, white iron (II) D, white iron (II) E, white iron (III) A, white iron Grade, Type, or Number
F45000 F45001 F45002 F45003 F45004 F45005 F45006 F45007 F45008 F45009
nickel-chromium irons nickel-chromium irons nickel-chromium irons nickel-chromium irons chromium-molybdenum irons chromium-molybdenum irons chromium-molybdenum irons chromium-molybdenum irons chromium-molybdenum irons chromium-molybdenum irons
550-600 550-600 550-600 400-600 400-600 400-600 400-600 400-600 400-600 400-600
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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 40-A 45-A 45 50-A 50 55-A 50 60-A 60
T150
FGG10 FGG15
GG10 GG15
T220
FGG20 FGG25
GG20 GG25
F12801 F13101
FGG30
GG30
F13501 F13801 F14101 Gray, Austenitic ASTM A436 F41000 F41001 F41002 F41003 F41004 F41005 F41006 F41007 Malleable Iron ASTM 602, SAE J158, ASTM A7 F20000
FGG35 FGG40
GG35 GG40
FGL400
1 1b 2 2b 3 4 5 6
F22200 F22400
40
Germany
Great Britain
International
Italy
Japan
Sweden
Gray Cast Iron ASTM 48, ASME SA278, ASTM A159, SAE J431 Ch130 Ch170 Ch190 Ch210 Ch230 G10 G15 200 250 G20 G25 FC20-3 FC250-4 0212-00 0215-00 0217-00 0219-00 0221-00 0223-00 0110-00
100 150
FC10-1 FC15-2
GG-25 GG-30
300
300
G30
FC25-4 FC30-5
0125-00
GG-35
350
350
G35
FC350-6
400 Gray, Austenitic ASTM A436 GGL-NiCuCr1562 GGL-NiCuCr1563 GGL-NiCr202 GGL-NiCr203 GGL-NiCr303 GGL-NiSiCr3055 F1 F1 F2 L-NiCr202 F2 F3 L-NiCuCr1562 L-NiCuCr1563 L-NiCr202 L-NiCr203 L-NiCr303 L-NiSiCr2053 L-NiSiCr3055 L-Ni35 S2 Malleable Iron ASTM 602, SAE J158, ASTM A7
0523-00
41
F32800
60-40-18 D4018
370-17
FNG38-17
715 716
F33100
65-45-12 D4512
400-12
FNG42-12
F33101 F33800
F34100 F34800
5316 100-70-03 D7003 700-0 800-2 FNG70-2 FNG80-2 707 708 FGS700-2 FGS800-2 FGA900-2
120-90-02
D-2
S-NC202
F43001
D-2B
L-NiCr203 S-NiCr203
S-NC203
S-Ni22
S-N22 S-NC303
F43010
D-2M-1 D-2M-2
S-NM234
42
Great Britain
International
Italy
Japan
Sweden
GGG-40
GS370-17
GGG-50
GS400-12
FDC45-2
GGG-60
500/7
500-7
GS500-7
FCD50-3 FCD60-4
0727-02
GGG-70
700/2 800/2
GS700-2 GS800-2
FCD70-5 FCD80-6
900/2
GGG-NiCr202
S2 S2W
S-NiCr202
GGG-NiCr203
S2B
S-NiCr203
S2C S3 S3
GGG-NiMn234
S2M
S-NiMn234
43
Material Characteristics
out-of-balance condition may exist chucking on cast surface can be difficult tendency to break out during exit from cut contains abrasive elements; sand may be embedded in the cast surface potential for chatter on thin wall sections corners and thin sections can be chilled (hard and brittle) potential scale, inclusions
workpiece breakout 1. Use PVD-coated grade KC5010 at moderate to low speeds. 2. Reduce feed rate during exit. 3. Pre-chamfer casting edge at exit. 4. Increase toolholder lead angle. workpiece chatter 1. Use a smaller nose radius. 2. Apply insert geometries that are free-cutting, such as MG-FN and MG-RP. 3. Increase feed to stabilize workpiece. 4. Shorten toolholder or bar overhang. 5. Check toolholder and workholding system for rigidity. 6. Use Top Notch Turning (GX-T style) insert for increased tooling rigidity.
44
Material Characteristics
graphite is in spherical form, rather than flake form customary in gray cast iron hard spots are common concentrations of carbide in the structure workpiece material structure may vary dramatically machining difficulties may develop from flank and crater wear on the tool higher tensile strength requires good rigidity in machining system decreased tool life should be expected, compared to machining gray or malleable cast iron
Material Characteristics
graphite is in irregular-shaped nodules, rather than flake form customary in gray cast iron 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. 8. Choose grade Kyon 3500 to replace Kyon 3400 for heavy interruptions. catastrophic failure 1. Reduce speed and feed. 2. Use a T-land plus hone edge prep. torn or dull workpiece 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
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.
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
46
Heat Deformation
Depth-of-Cut Notching
Thermal Cracking
Built-Up Edge
Apply coated grades or cermets. Utilize coolant. Edge prep (smaller hone).
Crater
Catastrophic Breakage
Corrective Action Utilize stronger insert geometry grade. Reduce feed rate.
*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
Pre-chamfer workpiece whenever possible to avoid workpiece material breakout and interrupted cut shock damage to insert edge.
48
3. T-land plus hone 1. T-land 2. hone 3. T-land plus hone 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. 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.
49
insert geometry
profile
.006 .016
.040 .100
.060 .160
.100 .250
.200 .500
wiper, finishing
MG-FW
MG-MW
wiper, roughing
MM-RW
(single sided)
finishing
MG-FN
medium machining
MG-UN
roughing
MG-RP
roughing
MG-RN
heavy roughing
MM-RM
(single sided)
heavy roughing
MM-RH
(single sided)
50
insert geometry
profile
.006 .016
.025 .060
.040 .100
.060 .160
.100 .250
.200 .500
wiper, finishing
MT-FW
MT-MW
fine finishing
MT-11
fine finishing
MT-UF
finishing
MT-LF
medium machining
MT-MF
51
KT315
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.
C3 C7
KC5010
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.
C3 C4
KC9315
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 youre looking for high productivity performance, the KC9315 grade is an ideal choice. 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.
C3 - C4 K10 - K25
KC9325
C2 - C3 K15 - K30
KY1310*
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. *KY1310 will be available January 2004.
K05-K15
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. composition: Pure silicon nitride grade. application: Maximum toughness; used at high feed rates for rough machining of gray cast iron, including machining through interruptions.
C3
K10 - K30
KY3500
C2
KB9640
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.
C1
K05-K15
52
KY3500
53
KENNAMETAL
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tool-buying costs by as much as 90%! tool-inventory costs by up to 50%! tool-supply costs by nearly 30%!
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54
Technical Information
page
Wiper Insert Application Guidelines . . . . . . . . . . . Conversion Tables . . . . . . . . . . . . . . . . . . . . . . . . . Nose Radius Selection for Surface Finish . . . . . . . . . . . Insert Size Selection Guide
...................... ....................
56 60 61 62 63 66
55
Double Productivity
Kennametals new wiper geometries allow you to double your current feed rate and still achieve surface finishes comparable to conventional inserts. Youll also see equivalent or better tool life using the appropriate KENNA PERFECT grade specifically designed for your workpiece material.
doc ................0.050 feed ................0.020 ipr speed..............1,100 sfm finish ..............60 Ra ( in.)
56
insert
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) 14 30 50 80 (0,3) (0,75) (1,3) (2)
3/8 IC
1/2 IC
23 41 63 91 120 160 200 250 (0,6) (1) (1,6) (2,2) (3) (4) (5) (6,2)
3/4 + 1 IC
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
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Kenloc Toolholders
Kenloc Toolholders
SStyle Inserts
surface with wiper effect surface with standard insert edge
Kenloc Toolholders
NOTE: The holder guidelines above also apply to ceramic/PCBN wiper inserts in similar insert shapes; i.e.: CNGA, CNGX, DNGA, etc.
58
-FW
Finishing Wiper
-MW
Medium Machining Wiper
Surface Finish
Theoretical Surface Finish Ra
in. (m) insert FW , MW feed rate ipr (mm/rev) .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 6 14 22 35 49 (0,03) (0,15) (0,35) (0,55) (0,90) (1,25)
1/4 IC
3/8 IC
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)
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
inch to metric
diameter 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 diameter 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
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
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
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
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
Turning Formulas
to find formula
d x rpm 3.82 sfm x 3.82 d sfm 3.27 mpm x 3.27 ipm rpm ipr x rpm inch x 25.4 mm 25.4 loc ipr x sfm (minutes)
NOTE: Values in shaded areas are beyond normal range and given for information only.
doc inches .010 .015 .030 .050 .100 .125 .150 .250 .375 .500 feed ipr .003 .005 .005 .006 .007 .008 .009 .010 .011 .012 mm/rev .076 .120 .127 .152 .178 .203 .229 .254 .279 .305 mm 0,254 0,381 0,762 1,270 2,540 3,175 3,810 6,350 9,525 12,700 sfm 300 400 500 600 800 1000 1200 2000 4000 10000
speed m/min. 91 122 152 183 244 305 366 610 1219 3048
Abbreviations
sfm = rpm = mpm = ipr = ipm = d = surface feet per minute revolutions per minute meters per minute inches per revolution inches per minute diameter millimeters length of cut
surface finish (Ra) inch m 492 12,5 248 6,3 126 3,2 63 1,6 31 0,8 16 0,4
mm = loc =
60
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. Follow the horizontal line corresponding to the desired theoretical finish to where it intersects the diagonal line corresponding to the intended feed rate. Project a line downward to the nose radius scale and read the required nose radius. If this line falls between two values, choose the larger value. 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: Peaks produced with a small radii insert (top) compared to those produced with a large radius insert (bottom).
*NOTE: See pages 57-59 for radius and surface finish specifications using wiper-style inserts.
61
insert shape
IC
cutting edge length .250 .375 .500 .625 .750 1.000 .275 .433 .590 .748
C-80 Diamond
D-55 Diamond
.250 .375 .500 .625 .750 1.000 .250 .375 .500 .625
R-Round
.375 .500 .625 .750 1.000 .375 .500 .625 .750 1.000 .250 .375 .500 .625
.188 .250 .313 .375 .500 .375 .500 .625 .750 1.000 .433 .630 .866 1.060 ..075 ..120
.112 .200 .250 .300 .400 .150 .250 .313 .375 .500
.112 .200 .250 .300 .400 .150 .250 .313 .375 .500
S-Square
T-Triangle
V-35 Diamond
.375 .500
.630 .866
.045
.060
.070 .120
W-Trigon
.075 .100
.100 .150
.120 .200
62
CUSTOMER NAME
HARDNESS
PART DESCRIPTION
OPERATION
CONDITION OF MACHINE
HP
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 . . . . . . . . . . . . Kenloc Negative Inserts . . . . . . . . . . . . . . . . Screw-On Inserts . . . . . . . . . . . . . . . . . . . . . . . Top Notch Turning Inserts . . . . . . . . . . . . . . . . . Kendex Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 68 81 91 94
65