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Metallurgy and Machinability

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.

Selected ASTM Standards for Cast Irons


Unalloyed Cast Irons A47 A48 A126 A159 A197 A220 A278 A319 A395 A476 A536 A602 Malleable iron castings Gray iron castings Gray iron castings for valves, flanges, and pipe fittings Automotive gray iron castings Cupola malleable iron Pearlitic malleable iron castings Gray iron castings for pressure-containment with temperatures up to 345 C (650 F) Gray iron castings for elevated temperatures non-pressure containing parts Ferritic ductile iron pressure-retaining castings for elevated temperatures Ductile iron castings for papermill dryer rolls Ductile iron castings Automotive malleable iron castings

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-Silicon Cast Irons A532 Abrasion-resistant cast irons

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

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Metallurgy and Machinability


White cast irons, also known as abrasion-resistant cast irons, are an iron-carbon alloy in which the carbon content exceeds 1.7%. White cast iron does not have any graphite in the microstructure. Instead, the carbon is present either as ironcarbide or complex iron-chromium carbides (Figure 1), which are responsible for high hardness and resistance to abrasive wear. White iron shows a white, crystalline fracture surface because fracture occurs along the carbide plates. White iron can be produced either throughout the section or only on the surface by casting the molten metal against graphite or metal chill. In the latter case, it is referred to as chilled iron. Corrosion-resistant cast irons obtain their resistance to chemical wear primarily from their high alloy content of silicon, chromium, or nickel. Depending on which of the three alloys dominates the compositions, the corrosion-resistant material can be ferritic, pearlitic, martensitic, or austenitic. Machinability Alloy Cast Irons White irons and corrosion-resistant high-silicon (14.5%Si) gray irons are the most difficult cast irons to machine. Alloyed white irons such as nickel-hard (Ni-hard) alloys and high-silicon irons (ASTM A518) are generally ground to size or turned with a polycrystalline cubic boron nitride (PCBN) tool material such as Kennametal grades KB9640, KD120, or KB5625 Gray cast irons (ASTM A48, A126, A159, ASME AS278 and SAE J431) are named such because their fracture has a gray appearance and consists of graphite flakes embedded in a matrix of ferrite or pearlite, or a mixture of the two depending on the composition and cooling rate (Figures 2a-2d). Ferrite is a soft, low-carbon alpha iron phase with low tensile strength but high ductility. Pearlite consists of lamellar plates of soft ferrite and hard cementite. Gray irons contain 2.5 to 4% carbon (C), 1-3% silicon (Si), and manganese (Mn) (~0.1% Mn in ferritic gray irons and as high as 1.2% Mn in pearlitic gray irons). Sulfur (S) and phosphorus (P) may be present as residual impurities. Manganese is deliberately added to neutralize the sulfur. The resulting manganese sulfide is uniformly distributed in the matrix of gray iron as inclusions. ASTM specification A48 classifies gray cast irons in terms of tensile strength (class 20 with 20 ksi minimum tensile strength to class 60 with 60 ksi minimum tensile strength). The fluidity of liquid gray iron and its expansion during solidification due to the formation of graphite are responsible for the economic production of shrinkage-free, intricate castings such as engine blocks. Most gray iron components are used in the as-cast condition. However, for specific casting requirements, they can be heat treated (annealed, stress relieved, or normalized). Other heat treatments include hardening and tempering, austempering, martempering, and flame or induction hardening.

Figure 2a: Type C flake graphite in gray iron

Figure 2b: Pearlite-ferrite gray cast iron

Figure 2c: Coarse pearlite in gray cast iron

Figure 2d: Pearlitic gray cast iron

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
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Photomicrographs courtesy of Buehler Ltd., Lake Bluff, Illinois, USA, www.buehler.com

Metallurgy and Machinability


and pearlite increases, tool life decreases rapidly. Both iron and alloy carbides, when present as large particles, are detrimental to tool life. Irons with higher phosphorous contents (~0.4%) form a hard constituent called steadite, which has a detrimental effect on tool life. Gray cast irons are productively turned and milled with multi-layered alumina and TiCN coated inserts. The substrate tool material can be either carbide or silicon nitride-based ceramic. Cermet grades such as KT315 are ideal for light depth-ofcut applications. A pure silicon nitride grade such as KY3500 often yields the highest productivity on general turning and milling applications at high speeds. Drilling applications are highly dependent on the drill geometry as well as drill grade. Kennametal solid carbide drills in the TF (triple flute) and SE (sculptured edge) geometries in TiALN-coated grades KC7210 and KC7215 are the most desirable. For indexable insert drilling applications, TiALN-coated KC7725 and alumina coated KC7935 grades are the first choice for high-speed, high productivity applications. Ductile (nodular) irons (ASTM A395, A476, A439, A536 and SAE J434), previously known as nodular iron or spheroidal-graphite cast iron, contain nodules of graphite embedded in a matrix of ferrite or pearlite or both (Figures 3a-3c). The graphite separates as nodules from molten iron during solidification because of additives cerium (Ce) and magnesium (Mg) introduced in the molten iron before casting. The nodules act as crack arresters and impart ductility to the material. By contrast, neither white iron nor gray iron shows a significant amount of ductility. Ductile iron is of higher purity (low phosphorus [P] and sulfur [S]) and is stronger than gray iron. With a high percentage of graphite nodules present in the microstructure, the matrix determines the mechanical properties of ductile iron. Table B compares the composition of ductile iron with that of gray iron and malleable iron. The ASTM classifies different grades of ductile irons in terms of tensile strength in ksi, yield strength in ksi, and elongation in percent. For example, ASTM A536 specifies five standard ductile iron grades: 60-40-18 / 65-45-12 (ferritic ductile iron), 80-55-06 (ferritic-pearlitic ductile iron), 100-70-03 (pearlitic ductile iron), and 120-90-02 (quenched and tempered martensitic ductile iron). Ferritic ductile iron the ferrite matrix provides good ductility and impact resistance and tensile strength equivalent to low-carbon steel. Ferritic ductile iron can be produced as-cast or may be given an annealing treatment to obtain maximum ductility and low-temperature toughness. Ferritic-pearlitic ductile irons usually produced in the as cast condition and feature both ferrite and pearlite in the microstructure. Properties are intermediate between ferritic and pearlitic ductile irons.

Figure 3a: Ferritic annealed ductile iron

Figure 3b: Pearlite/ferrite ductile iron

Figure 3c: Coarse lamellar pearlite in ductile iron

Table B Typical composition ranges for unalloyed cast irons


composition % material gray iron malleable iron ductile iron total carbon 3.25-3.50 2.45-2.55 3.60-3.80 manganese silicon (Si) 1.80-2.30 1.40-1.50 1.80-2.80 chromium (Cr) 0.05-0.45 0.04-0.07 0.03-0.07 nickel (Ni) 0.05-0.20 0.05-0.30 0.05-0.20 molybdenum (Mo) 0.05-0.10 0.03-0.10 0.01-0.10 copper (Cu) 0.15-0.40 0.03-0.40 0.15-1.00 phosphorus (P) 0.12 max 0.03 max 0.03 max sulfur (S) 0.15 max 0.05-0.07 0.002 max cerium (Ce) ... ... 0.005-0.20 magnesium (Mg) ... ... 0.03-0.06

0.50-0.90 0.35-0.55 0.15-1.00

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Metallurgy and Machinability


Pearlitic ductile irons - the pearlitic matrix provides high strength, good wear resistance, and moderate ductility and impact resistance. While the aforementioned three types of ductile iron are most common and used in as-cast condition, ductile irons also can be alloyed and/or heattreated to provide additional grades as follows: Martensitic ductile irons are produced using sufficient alloy additions to prevent pearlite formation, and a quench-and-temper heat treatment to produce a tempered martensitic matrix. These materials have a high strength and wear resistance but lower levels of ductility and toughness. Bainitic ductile irons are produced through alloying and/or by heat treatment to provide a hard, wear-resistant material. Austenitic ductile irons are produced through alloying additions to provide good corrosion and oxidation resistance, magnetic properties, and strength and dimensional stability at high temperatures. Machinability - Ductile Irons The spherical graphite in ductile iron acts similar to the flake graphite in gray iron in chip breaking and lubrication in machining. Machinability increases with silicon content up to 3%, but decreases significantly at higher silicon levels. As in the case of gray cast iron, machinability decreases with increasing pearlite content in the microstructure. Finer pearlite structures also decrease machinability. Still, pearlitic ductile irons are considered to have the best combination of machinability and wear resistance. Cast irons with tempered martensitic structure have a better machinability than pearlite with similar hardness. Other microstructures such as acicular bainite and acicular ferrite formed during heat treatment of ductile irons have machinability similar to martensite tempered to the same hardness. The higher tensile strength of ductile irons compared to gray cast iron requires better rigidity within the machining system. Tool performance life may be slightly lower if run at gray cast iron surface speeds. Ductile cast irons can be productively turned and milled with multi-layered alumina and TiCN or PVD TiALN-coated inserts but at slightly slower speeds than gray cast irons. Malleable cast irons (ASTM A602 and A47) consist of uniformly dispersed and irregularly shaped graphite nodules (often called temper graphite because it is formed by the dissolution of cementite in the solid state) embedded in a matrix of ferrite, pearlite (Figure 4), or tempered martensite. Malleable iron is cast as white iron and then heat-treated to impart ductility to an otherwise brittle material. Malleable iron possesses considerable ductility and toughness due to the nodular graphite and a lower carbon metallic matrix. It has good fatigue strength and damping capacity, good corrosion resistance, good magnetic permeability, and low magnetic retention for magnetic clutches and brakes. Malleable iron, like medium-carbon steel, can be heat treated to obtain different matrix microstructures (ferrite, pearlite, tempered pearlite, bainite, tempered martensite, or a combination of these) and mechanical properties. Malleable and gray irons differ in two respects: the iron carbide is partially or completely dissociated in malleable cast iron; the dissociation occurs only when the alloy is solid. However, the dissociation in gray cast iron occurs during the early stages of solidification; hence the difference in the character of graphite in each material.

Figure 4: Coarse pearlite in annealed malleable iron

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
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Photomicrographs courtesy of Buehler Ltd., Lake Bluff, Illinois, USA, www.buehler.com

Metallurgy and Machinability


treatment. The microstructure consists of spheroidal graphite in a matrix of acicular ferrite and stabilized austenite (called ausferrite) (Figure 5). The fine-grained acicular ferrite provides an exceptional combination of high tensile strength with good ductility and toughness. ADI can be given a range of properties through control of austempering conditions. Compared to conventional grades of ductile iron, ADI offers twice the tensile strength for a given level of elongation. Compacted graphite iron (CGI) (ASTM A842) has a microstructure in which the graphite is interconnected like the flake graphite in gray cast iron, but the graphite in CGI is coarser and more rounded (Figure 6). In other words, the structure of CGI is between that of gray and ductile iron. The graphite morphology allows better use of the matrix, yielding higher strength and ductility than gray irons. The interconnected graphite in CGI provides better thermal conductivity and damping capacity than the spheroidal graphite in ductile iron. Although the CGI is less section-sensitive than gray iron, high cooling rates are avoided because of the high propensity of the CGI for chilling and high nodule count in thin sections.

Figure 5: Austempered ductile iron

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.
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Photomicrographs courtesy of Buehler Ltd., Lake Bluff, Illinois, USA, www.buehler.com

Figure 6: Compacted graphite

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.

Metallurgy and Machinability


Gray Cast Irons & Gray, Austenitic
standard materials UNS tensile strength ASTM A159 & SAE J431 ASTM A278 & ASME AS278

hardness HB

ASTM 48

ASTM A126

ASTM A319

ASTM A436

Gray Cast Irons

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

Class l Class ll Class lll

Gray, Austenitic

F41000 F41001 F41002 F41003 F41004 F41005 F41006 F41007

1 1b 2 2b 3 4 5 6

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Metallurgy and Machinability


Malleable Cast Irons & Pearlitic, Martensitic
standard materials UNS tensile strength yield strength ASTM A602 & SAE J158

hardness HB

ASTM A47

ASTM A220

Malleable Cast Irons

F20000 F20001 F20002 F20003 F20004 F20005 F22200 F22400

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

M3210 M4504 M5003 M5503 M7002 M8501

Malleable, Pearlitic & Martensitic

F22830 F23130 F23131 F23530 F24130 F24830 F25530 F26230

Grade, Type, or Number

Ductile Cast Iron & Ductile, Austenitic


standard materials UNS tensile strength yield strength ASTM A395 A476 A536

hardness HB

ASTM A439

ASTM A571

AMS

SAE J434

MIL-I24137

Ductile Cast Iron

F30000 F32800 F33100 F33101 F33800 F34100 F34800 F36200

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

DQ & T D4018 D4512 (A) D5506

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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Metallurgy and Machinability


Austempered Ductile Iron (ADI)
standard materials UNS tensile strength yield strength hardness HB

ASTM A897-90 125-80-10 150-100-7 175-125-4 200-155-1 230-185 Grade, Type, or Number

Austempered Ductile Iron (ADI)

n/a n/a n/a n/a n/a

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.

269-321 302-363 341-444 388-477 444-555

Compacted Graphite Iron (CGI)


standard materials UNS tensile strength yield strength hardness HB

ASTM A842 250 300 350 400 450 Grade, Type, or Number

Compacted Graphite Iron (CGI)

n/a n/a n/a n/a n/a

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%

179 Max. 143-207 163-229 197-255 207-269

Nickel (Ni) Hard / White Cast Iron


standard materials UNS properties hardness HB

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

Austempered Ductile Iron (ADI)

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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Metallurgy and Machinability


Cast Iron Cross-Reference / Workpiece Comparison Table
UNS USA Australia Belgium Denmark France

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

FGL150 FGL150A FGL200A FGL250A FGL200 FGL250 FGL300A

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

FGL300 FGL350A FGL400A FGL350

FGL400

1 1b 2 2b 3 4 5 6

L-NiCuCr1562 L-NiCuCr1563 L-NiCr202 S-NiCr202 L-NiCr303 S-NiCr303 NiSiCr3055 L-Ni35 S-NiCr353

L-NUC1562 L-NUC1563 L-NC202 L-NC203

L-NSC2053 L-NSC3055 L-N35

F22200 F22400

M3210 M4504 M5003 M5503 M7002 M8501 32510 35018

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Metallurgy and Machinability

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

GG-10 GG-15 GG-20

100 150 180 200 220 250 260

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

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Metallurgy and Machinability


Cast Iron Cross-Reference / Workpiece Comparison Table
UNS Ductile Cast Iron ASTM A395, ASTM A476, ASTM A536, SAE J434 USA Australia Belgium Denmark France

F32800

60-40-18 D4018

370-17

FNG38-17

715 716

FGS350-22 FGS350-22L FGS400-15 FGS400-18 FGS400-18L

F33100

65-45-12 D4512

400-12

FNG42-12

F33101 F33800

5315 80-55-06 D5506 500-7 FNG50-7 727 FGS500-7

F34100 F34800

5316 100-70-03 D7003 700-0 800-2 FNG70-2 FNG80-2 707 708 FGS700-2 FGS800-2 FGA900-2

F36200 Ductile Cast Iron, Austenitic ASTM A439 F43000

120-90-02

D-2

S-NC202

F43001

D-2B

L-NiCr203 S-NiCr203

S-NC203

F43002 F43003 F43004 F43005 F43006 F43007

D-2C D-3 D-3A D-4 D-5 D-5B D-5S

S-Ni22

S-N22 S-NC303

S-NiCr301 S-NiSiCr3055 S-Ni35

S-NC301 S-NSC3055 S-N35 S-NC353

F43010

D-2M-1 D-2M-2

S-NM234

42

Metallurgy and Machinability

Germany Ductile Cast Iron

Great Britain

International

Italy

Japan

Sweden

ASTM A395, ASTM A476, ASTM A536, SAE J434

GGG-40

350/22 350/22L40 400/18 400/18L20

350-22 350-22L 400-15 400-18 400-18L

GS370-17

FCD37-0 FCD40-1 0717-00 0717-02 0717-15

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

700-2 800-2 900-2

GS700-2 GS800-2

FCD70-5 FCD80-6

GGG-80 Ductile Cast Iron, Austenitic ASTM A439

900/2

GGG-NiCr202

S2 S2W

S-NiCr202

GGG-NiCr203

S2B

S-NiCr203

GGG-Ni22 GGG-NiCr303 GGG-NiCr301 GGG-NiSiCr3055 GGG-Ni35 GGG-NiCr353

S2C S3 S3

S-Ni22 S-NiCr303 S-NiCr301 S-NiSiCr3055 S-Ni35 S-NiCr353

GGG-NiMn234

S2M

S-NiMn234

43

Expert Application Advisor Cast Irons


Gray Cast Iron and Austenitic, Gray Iron (120-320 HB)
ASTM: A48I: class 20, 25, 30, 35, 40, 45, 50, 55, 60 ASTM: 126: class A, B, C ASTM: A159 & SAE: J431; G1800, G2500, G3000, G3500, G4000 ASTM: A436; 1, 1b, 2, 2b, 3, 4, 5, 6

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.

Common Tool Application Considerations Problems & Solutions


excessive edge wear 1. Use grade KC9315 or KT315 if running at moderate to high speeds. 2.. Use silicon nitride-based ceramic grades Kyon 3500 or Kyon 1310, or PCBN grades, if running at ultra-high speeds. Machining system must have the rigidity and horsepower required to run at ultra-high speeds. 3. Increase the feed to reduce in-cut time. chipping 1. Increase toolholder lead angle. 2. Use a grade with good edge strength, such as grade KC9325. 3. Ensure proper insert seating. 4. Use strong, negative-rake insert geometries such as MA, GX-T or GA-T. 5. Use inserts with an MT-land edge prep.

44

Expert Application Advisor Cast Irons


Ductile Iron (120-320 HB)
ASTM: A395, A476, A536; 60-40-18, 65-45-12, 80-55-06, 80-60-03, 100-70-03, 120-90-02 SAE: J434; DQ & T, D4018, D4512, D5506, D7003 AMS: 5315, 5316 ASTM: A439. A571; D2, D2B, D2C, D3, D3A, D4, D5, D5B, D2M

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

Malleable Cast Iron (120-320 HB)


ASTM: A47: 32510, 35018 ASTM: A602 & SAE J158; M3210, M4504, M5003, M5503, M7002, M8501 ASTM: A220; 40010, 45008, 45006, 50005, 60004, 70003, 80002, 90001

Material Characteristics
graphite is in irregular-shaped nodules, rather than flake form customary in gray cast iron generally easy to machine at aggressive conditions.

Common Tool Application Considerations Problems & Solutions


excessive edge wear 1. Apply grade KC9315 to achieve higher speeds and longer tool life. 2. Use grade KC9325 for general purpose and interrupted cutting. 3. Apply grade KC9315 or KT315 if edge wear is excessive in smooth cuts. 4. Use ceramic grade Kyon 3400. Increase speed and make sure the machining set up and workpart clamping is rigid. 5. Increase feed to reduce time in cut. crater wear 1. Apply grade KC9315 or KT315. 2. Reduce speed to lower the heat at cutting edge. 3. Apply ceramic grade Kyon 3400 when machining at high speeds. 4. Apply large amounts of flood coolant.

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

Expert Application Advisor Cast Irons


Austempered Ductile Iron (269-444 HB)
ASTM: A897; 125-80-10, 150-100-7, 175-125-4, 200-155-1, and 230-185

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.

Compacted Graphite Iron (CGI) (179-269 HB)


ASTM: A842; Grade 250, 300, 350, 400, 450

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

Compacted graphite irons are machined similar to lower-strength ductile irons.

Kennametal Tooling System Solutions


KM Kenclamp Tooling Catalog 2014
Our newest quick-release (1.5 turns) clamping design Robust clamping design reduces chatter and improves tool life Ensures insert repeatability and seating Fewer moving parts vs. competitive systems Request A02-132!

46

Failure Mechanism Analysis


Edge Wear* Chipping

Corrective Action Increase feed rate. Reduce speed (sfm).

Use more wear resistant grade. Apply coated grade.

Corrective Action Utilize stronger grade. Consider edge preparation.

Check rigidity of system. Increase lead angle.

Heat Deformation

Depth-of-Cut Notching

Corrective Action Reduce speed. Reduce feed.

Reduce depth-of-cut (doc). Use grade with higher hot hardness.

Corrective Action Change lead angle. Consider edge preparation.

Apply different grade. Adjust feed.

Thermal Cracking

Built-Up Edge

Corrective Action Properly apply coolant. Reduce speed.

Reduce feed. Apply coated grades.

Corrective Action Increase speed (sfm). Increase feed rate.

Apply coated grades or cermets. Utilize coolant. Edge prep (smaller hone).

Crater

Catastrophic Breakage

Corrective Action Reduce feed rate. Reduce speed (sfm).

Apply coated grades or cermets. Utilize coolant.

Corrective Action Utilize stronger insert geometry grade. Reduce feed rate.

Reduce depth-ofcut (doc). Check rigidity of system.

*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

Machinability Data Cast Iron


Gray Cast Iron
The ideal turning insert geometry for machining gray cast iron should have the following characteristics: square or diamond shaped for maximum strength negative insert geometry for maximum strength and number of cutting edges minimum or no positive-rake chip-forming insert geometry for maximum edge strength medium edge hone on carbide inserts and a T-land edge prep on ceramic/sialon-grade inserts

Ductile Cast Iron


The ideal turning insert geometry for machining ductile cast iron should have the following characteristics: square or diamond shaped for maximum strength negative insert geometry for maximum strength and number of cutting edges positive-rake chip-forming insert geometry for freer cutting action and chip control light edge hone on carbide inserts and a T-land edge prep on ceramic/sialon-grade inserts

Pre-chamfer workpiece whenever possible to avoid workpiece material breakout and interrupted cut shock damage to insert edge.

48

Insert Edge Preparation


Edge Preparation for Kennametals Advanced Cutting Tool Materials
Edge preparation is the term for the intentional modification of the cutting edge of an indexable insert to enhance its performance in a metalcutting operation. Ceramic cutting tool materials have a much higher hardness, but lower toughness, compared to conventional carbide materials. Because of this, ceramic materials have good bulk strength but lower edge strength versus carbide. To optimize performance of ceramic cutting tools, it is critical that tool material, workpiece material, and machining conditions be considered relative to edge preparation. To achieve optimum edge preparation, make the minimum amount of modification necessary to distribute forces sufficiently enough to prevent chipping and catastrophic insert failure. Edge preparations for standard inserts made with specific ceramic grades are determined by target applications and listed in the KENNA PERFECT insert selection system. There are three choices of edge preparation for ceramic materials: There is a tradeoff to the benefits of this edge preparation. Increasing the width T of the T-land or the angle A increases the overall cutting forces acting on the insert. This can negatively affect the wear rate of the insert and/or deformation of a thin-walled workpiece. For most cast iron turning applications, use a T-land width smaller than the feed rate. For heavily interrupted turning, hard turning (workpiece >50 HRC), and milling applications, use a T-land width larger than the feed rate. 2. Hone Hones protect the insert cutting edge by eliminating the sharp edge and distributing the cutting forces over a larger area. Hones generally are recommended for continuous or finishing operations; however, depending on the workpiece material, they can be used for interrupted or heavy cutting.

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

Chip Control Geometries


Kenloc Inserts
operation insert style application
feed rate inches

insert geometry

profile

.0015 .0025 .004 .004 .006 .010

.006 .016

.010 .016 .025 .025 .040 .060

.040 .100

.060 .160

.100 .250

.200 .500

depth of cut inches


.008 - .016 (0,2 - 0,4) .010 - .080 (0,3 - 2,0)

wiper, finishing

MG-FW

wiper, medium machining

MG-MW

.012 - .024 (0,3 - 0,6) .030 - .200 (0,8 - 5,1)

wiper, roughing

MM-RW
(single sided)

.010 - .050 (0,3 - 1,3) .050 - .500 (1,3 - 12,7)

finishing

MG-FN

.005 - .012 (0,1 - 0,3) .010 - .100 (0,3 - 2,5)

medium machining

MG-UN

.008 - .020 (0,2 - 0,5) .030 - .150 (0,8 - 3,8)

roughing

MG-RP

.010 - .025 (0,3 - 0,6) .045 - .250 (1,1 - 6,4)

roughing

MG-RN

.010 - .025 (0,3 - 0,6) .045 - .250 (1,1 - 6,4)

heavy roughing

MM-RM
(single sided)

.010 - .040 (0,3 - 1,0) .050 - .500 (1,3 - 12,7)

heavy roughing

MM-RH
(single sided)

.015 - .050 (0,4 - 1,3) .050 - .500 (1,3 - 12,7)

feed rate (mm)


0,04 0,063 0,01 0,1 0,16 0,25 0,16 0,4 0,25 0,63 0,4 1,0 0,63 1,6 1,0 2,5 1,6 4,0 2,5 6,3 5,0 10,0

depth of cut (mm)

50

Chip Control Geometries


Screw-On Inserts
operation insert style/ application
feed rate inches

insert geometry

profile

.0015 .0025 .004 .004 .006 .010

.006 .016

.010 .016 .025 .040

.025 .060

.040 .100

.060 .160

.100 .250

.200 .500

depth of cut inches


.003 - .013 (0,1 - 0,3) .008 - .060 (0,2 - 1,5)

wiper, finishing

MT-FW

wiper, medium machining

MT-MW

.005 - .020 (0,1 - 0,5) .016 - .130 (0,4 - 3,3)

fine finishing

MT-11

.003 - .010 (0,1 - 0,3) .008 - .050 (0,2 - 1,3)

fine finishing

MT-UF

.002 - .010 (0,1 - 0,3) .005 - .050 (0,1 - 1,3)

finishing

MT-LF

.007 - .015 (0,2 - 0,4) .030 - .090 (0,8 - 2,3)

medium machining

MT-MF

.009 - .017 0,2 - 0,4 .045 - .090 1,1 - 2,3

feed rate (mm)


0,04 0,063 0,01 0,1 0,16 0,25 0,16 0,4 0,25 0,63 0,4 1,0 0,63 1,6 1,0 2,5 1,6 4,0 2,5 6,3 5,0 10,0

depth of cut (mm)

51

Kennametal Grade System for Cutting Materials


Cermet (CERamics with METallic binders)
grade coating composition and application C class ISO class

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

K10 - K20 M10 - M20 P10 - P20

PVD Coated Carbide Grades


grade coating composition and application C class ISO class

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

K10 - K20 M10 - M20 P10 - P20

CVD Coated Carbide Grades


grade coating composition and application C class ISO class

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

Silicon Nitride-Based Ceramic


grade coating composition and application C class ISO class

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

K15 - K35 M15 - M30

PCBN Polycrystalline Cubic-Boron Nitride


grade coating composition and application C class ISO class

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

Kennametal Grade System for Cutting Materials


Gray Cast Irons
Ceramic Cutting Tools

Ductile Cast Irons


Ceramic Cutting Tools

KY3500

Carbide Cutting Tools

Carbide Cutting Tools

53

KENNAMETAL

TOOL MANAGEMENT SOLUTIONS


No matter how intricate your metalworking manufacturing operations or equipment, Kennametals new ToolBoss System, powered by our exclusive, built-to-suit ATMS software, will enable your machinists to spend more time machining parts far less energy locating tools.

ToolBoss System

Our unique, new, easy-to-use/ easy-to-audit tool dispenser can help reduce your:
s s s

tool-buying costs by as much as 90%! tool-inventory costs by up to 50%! tool-supply costs by nearly 30%!

www.kennametal.com

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

Tool Performance Report Form

Insert Identification System . . . . . . . . . . . . . . . . . . . . . . . .

55

Three Ways To Improve Your Turning Operations!


Kennametal introduces three new geometries that are the latest in state-of-the-art turning technology. Our new -RW (Roughing Wiper), -MW (Medium Wiper) and -FW (Finishing Wiper) inserts employ a modified corner radius design that delivers a superior surface finish compared to conventional inserts. This technology allows you to choose the metalcutting benefit thats most important to your application.

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.

Better Workpiece Finish


These new wiper geometries also will give you a markedly improved surface finish at your current machining conditions. Under typical conditions, youll see as much as a 250% improvement in the workpiece surface finish, all with inserts that meet your corner radius specifications. You choose! Either way, were sure youll agree that the new wiper geometries from Kennametal provide an outstanding way to optimize your turning operations. Please see the accompanying information for proper application guidelines.

Kennametal Wiper Technology MW Conventional Turning Insert


doc ............0.050 feed ..........0.012 ipr speed ........1,100 sfm finish ........160 Ra (in.)

doc ................0.050 feed ................0.020 ipr speed..............1,100 sfm finish ..............60 Ra ( in.)

56

Negative Wiper Inserts Application Technology


Surface Finish
Theoretical Surface Finish Ra
in. (m)

insert

feed rate ipr (mm/rev)

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

Corner Radius Configuration


CNMG and WNMG wiper inserts create a true corner radius on the workpiece, just as a standard insert does. DNMG and TNMG wiper inserts do not provide an exact corner radius on the workpiece. The radius produced falls within a .0025 tolerance band. (blue lines)

57

Negative Wiper Inserts Application Technology


C and WStyle Inserts
surface with wiper effect surface with standard insert edge

Kenloc Toolholders

CN . . 80 corner insert requires MCLN 5 reverse lead angle toolholder

CN . . 100 corner insert requires MCRN 15 lead angle toolholder

CN . . 100 corner insert requires MCKN 15 lead angle toolholder

WN . . 80 corner insert requires MWLN 5 reverse lead angle toolholder

D and TStyle Inserts


surface finish with wiper effect surface with designated insert nose radius surface finish with .016 radius

Kenloc Toolholders

DN . . 55 corner insert requires MDJN 3 reverse lead angle toolholder

TN . . 60 corner insert requires MTJN 3 reverse lead angle toolholder

SStyle Inserts
surface with wiper effect surface with standard insert edge

Kenloc Toolholders

SN . . 90 corner insert requires MSRN 15 lead angle toolholder

SN . . 90 corner insert requires MSKN 15 lead angle toolholder

NOTE: The holder guidelines above also apply to ceramic/PCBN wiper inserts in similar insert shapes; i.e.: CNGA, CNGX, DNGA, etc.

58

Positive Wiper Inserts Application Technology


Positive geometry wiper inserts offer the same advantages as negative style inserts. When compared to conventional inserts, feed rates can be doubled while maintaining surface finish, or surface finish can be improved by a multiple of 2.5 while maintaining productive feed rates.

-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 4 8 14 22 30 39 (0,02) (0,10) (0,20) (0,35) (0,55) (0,75) (1,00)

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)

CCMT and CPMT Inserts


surface with wiper effect surface with designated insert nose radius

Screw-On Toolholders and Boring Bars

C.MT 80 inserts require 5 reverse lead SCL toolholders.

C.MT 100 inserts require 15 lead SCK toolholders.

DCMT and DPMTStyle Inserts


surface finish with wiper effect surface with designated insert nose radius surface finish with .016 radius
SDN SDU SDJ

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

Application Guidelines Cast Iron


Conversion Charts hardness
Brinell HB Rockwell HRB HRC Brinell HB Rockwell HRB HRC

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

sfm rpm mpm sfm ipr ipm mm inches cut time

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

Application Guidelines Cast Iron


Nose Radius Selection and Surface Finish for Conventional Inserts*

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 Size Selection Guide


Cast Iron Geometries
maximum depth of cut

insert shape

IC

cutting edge length .250 .375 .500 .625 .750 1.000 .275 .433 .590 .748

finishing MG-FN MG-FW MA-T0820 T0420-FW

general purpose MG-UN MG-RP MG-MW

roughing MX-T0820 ..MA S0820

C-80 Diamond

D-55 Diamond

.250 .375 .500 .625 .750 1.000 .250 .375 .500 .625

.050 .075 .120

.150 .250 .313 .375 .500 .125 .175

.250 .313 .375 .500 .150 .200

.030 .060 .100

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

.030 .060 .100

.125 .175 .250

.150 .200 .300

V-35 Diamond

.375 .500

.630 .866

.045

.060

.070 .120

W-Trigon

.250 .375 .500

.157 .236 .315

.075 .100

.100 .150

.120 .200

62

Turning Tool Performance Report


COMPANY & LOCATION DATE ENGINEER

CUSTOMER NAME

MATERIAL TYPE AND CONDITION

HARDNESS

PART DESCRIPTION

CUTTING CONDITION (CIRCLE)

MACHINE & TYPE

OPERATION

CONDITION OF MACHINE

HP

CONSTANT SFM s YES s NO

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

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