Transcript Document

Greenleaf
GSN-100
®
®
Greenleaf GSN-100
GSN to GSN-100
Review of Silicon Nitrides
GSN-100
Description
Current data and successes
Turning
Gray Iron
Ductile Iron
Milling
Gray Iron
Ductile Iron
Other applications
GSN-100 vs. HSN-100 & 200
Silicon Nitrides
Greenleaf ® GSN-100
Developed for Cast Iron Applications
• Higher thermal shock resistance when compared to Whisker
Ceramics
• Lower high temperature stability compared to Whisker Ceramics
• Best in interrupted cutting due to high thermal shock resistance
• Scale
• Milling
®
Greenleaf GSN-100
An engineered blend of silicon
nitride and proprietary toughening
agents that redefine productivity in
the machining of cast iron.
GSN100 delivers outstanding tool
life at high cutting speeds in turning,
grooving and milling applications.
GSN-100 Test Data
GSN-100 Class 30
Gray Iron Turning
Gray Cast Iron, class 30, 20 R/C
• Competitor: GC-4187 K40C
• 2000 SFM (610 M/Min)
• .004 IPR plunge (0,10 mm/rev)
• .008 IPR turn (0,20 mm/rev)
• Greenleaf ® WG-6218-2A SG-0173
• 4000 SFM (1220 M/Min)
• .008 IPR plunge (0,20 mm/rev)
• .012 IPR turn (0,30 mm/rev)
Gray Cast Iron, class 30, 20 R/C
•This customer presently running competitor GC-4187 K40C grade and
completing 15 parts per insert with a cycle time of 13.44 minutes.
•Ran test with WG-6218-2A GSN-100 insert and completed 74 parts
per insert
•Cycle time 11.38 minutes
•5X greater tool life
•SFM is 2X present tool
•Feed rate is 4X present tool.
•Inserts ran parts for 3+ days before needing changed.
GSN-100 Class 435
Gray Iron Turning
Round 1 testing
The areas of focus for testing were:
Tool #1 Back Face and Rough Pilot
Area of
focus
Customer target: 150 parts per edge
Round 1 testing
Tool #1 - Back Face and Rough Pilot
Customer target: 150 parts per edge
INSERT JUSTIFICATION FOR TURNING
Date:
Customer:
Machine:
Coolant:
16-Jan-12
Operator:
Engineer:
HONOR VL-86
no
Cell 2B
INSERT COST PER PART
Operation:
Insert Manufacturer
Insert:
Edge Prep:
Grade:
Toolholder:
Present
back face
sumitomo
CNGX-434
Greenleaf
BNS800
CNGA-458
T2
GSN100
Insert Price ($):
# edges/insert
Price/ edge ($)
Passes/ edge
Insert cost/ Pass
$88.00
4
$22.00
150
$0.15
$9.74
4
$2.44
168
$0.01
Burden rate ($/hour)
Passes to finishing cut:
$60.00
1.00
$60.00
1.00
0
60
$0.00
0
60
$0.00
11.085
3000
1034
0.2
0.02
4.611
19.07
0.22
$0.22
11.085
3000
1034
0.2
0.02
4.611
19.07
0.22
$0.22
Cost to cut 1 Pass:
Cost to complete all passes:
$0.37
$0.37
$0.24
$0.24
Total cycle time (min):
0.22
0.22
BURDEN RATE COST OF PART
# of indexes/ pass
Time to index (sec)
Cost to index ($)
Part Diameter (in.):
speed (sfm)
RPM (rev/min)
DOC (in.)
Feed (in/rev)
LOC (in.)
removal rate (in3/min):
Cut time for 1 pass(min):
Cost to cut ($):
Parts/Year
Cost/Year
Cost savings/year
Cost/day
Cost/week
Cost/year
Total cost savings/year
93,600
$34,602.88
DIA. RANGE 8.779-13.39
SFM VARIES DUE TO DIAMETER RANGE
based on 15 parts/hr, 3 shifts, 5 days a week, cell 2B
$22,231.53
$12,371.36
Total manufacturing at 7000 Parts/day at 5 days per week
$2,587.82
$1,662.61
$12,939.11
$8,313.07
$672,833.83
$432,279.66
$240,554.17
Round 2 testing
The areas of focus for testing were:
Tool #3 – Inboard Bottom Face.
Tool #6 – Finish Pilot
Tool
#6
Tool
#3
Customer target: 300 parts per edge
Round 2 testing
Tool #3 – Inboard Bottom Face.
Customer target: 300 parts per edge
INSERT JUSTIFICATION FOR TURNING
Date:
Customer:
Machine:
Coolant:
13-Mar-12
Operator:
Engineer:
Merritech
no
15-30 VNC
Cell 1
INSERT COST PER PART
Operation:
Insert Manufacturer
Insert:
Edge Prep:
Grade:
Toolholder:
Present
bottom face
sumitomo
SNGX-434
Greenleaf
BNS800
Greenleaf
SNGN-454
T2
GSN100
Insert Price ($):
# edges/insert
Price/ edge ($)
Passes/ edge
Insert cost/ Pass
$88.00
8
$11.00
300
$0.037
$9.74
8
$1.22
400
$0.003
Burden rate ($/hour)
Passes to finishing cut:
$60.00
1.00
$60.00
1.00
# of indexes/ day @ 20 pcs/hr
Time to index (sec)
Cost to index ($)
1.6
60
$0.07
1.2
60
$0.05
Part Diameter (in.):
speed (sfm)
RPM (rev/min)
DOC (in.)
Feed (in/rev)
LOC (in.)
removal rate (in3/min):
Cut time for 1 pass(min):
Cost to cut ($):
13.14
2800
814
0.1
0.018
4.471
6.55
0.31
$0.31
13.14
2800
814
0.1
0.018
4.471
6.55
0.31
$0.31
Cost to cut 1 Pass:
Cost to complete all passes:
$0.41
$0.41
$0.36
$0.36
Total cycle time (min):
0.33
0.33
BURDEN RATE COST OF PART
Parts/Year
Cost/Year
124,800
$50,980.89
Savings/year @ 1 spindle
$6,276.14
DIA. RANGE 8.779-13.25
RPM VARIES DUE TO DIAMETER RANGE
based on 20 parts/hr, 3 shifts, 5 days a week, cell 1
$44,704.75
Savings/year @ 6 spindles
$37,656.84
Total manufacturing at 20 parts/hr, 3 shifts, 5 days a week on 3 machining centers
Savings/year @ 1 spindle
$18,828.42
Savings/year @ 6 spindles
$112,970.52
Round 2 testing
Tool #6 – Finish Pilot.
Customer target: 300 parts per edge
INSERT JUSTIFICATION FOR TURNING
Date:
Customer:
Machine:
Coolant:
13-Mar-12
Merritech
no
Operator:
Engineer:
15-30 VNC
Cell 1
INSERT COST PER PART
Operation:
Insert Manufacturer
Insert:
Edge Prep:
Grade:
Toolholder:
Present
finish pilot
sumitomo
CNGX-434
Greenleaf
BNS800
Greenleaf
CNGN-454
T9
GSN100
Insert Price ($):
# edges/insert
Price/ edge ($)
Passes/ edge
Insert cost/ Pass
$88.00
8
$11.00
300
$0.037
$9.74
8
$1.22
400
$0.003
Burden rate ($/hour)
Passes to finishing cut:
$60.00
1.00
$60.00
1.00
# of indexes/ day @20 pcs/hr
Time to index (sec)
Cost to index ($)
1.6
60
$0.07
1.2
60
$0.05
Part Diameter (in.):
speed (sfm)
RPM (rev/min)
DOC (in.)
Feed (in/rev)
LOC (in.)
removal rate (in3/min):
Cut time for 1 pass(min):
Cost to cut ($):
8.779
2500
1088
0.06
0.016
0.53
0.55
0.03
$0.03
8.779
2500
1088
0.06
0.016
0.53
0.55
0.03
$0.03
Cost to cut 1 Pass:
Cost to complete all passes:
$0.13
$0.13
$0.08
$0.08
Total cycle time (min):
0.06
0.05
BURDEN RATE COST OF PART
Parts/Year
124,800
Cost/Year
$16,696.53
Savings/year @ 1 spindle
$6,276.14
based on 20 parts/hr, 3 shifts, 5 days a week, cell 1
$10,420.39
Savings/year @ 6 spindles
$37,656.84
Total manufacturing at 20 parts/hr, 3 shifts, 5 days a week on 3 machining centers
Savings/year @ 1 spindle
$18,828.42
Savings/year @ 6 spindles
$112,970.52
GSN-100 Ductile Iron
Turning
65-45-12 Ductile Iron, 30 R/C
Prior: Greenleaf ® WG-6218-2A
HSN-100
• 1350 SFM (412 M/Min)
• .0065 IPT (0,17 mm/tooth)
• Machining 15 grooves/insert
Greenleaf ® WG-6218-2A
GSN-100
• 1350 SFM (412 M/Min)
• .0065 IPT (0,17 mm/tooth)
• Machining 75 grooves/insert
GSN-100 Cast Iron
Milling
Gray Cast Iron, as cast
We are running:
Milling Cutter- C404
Insert- CNGN-454 (CNGN120716)
Two Nests are used so both the 80⁰ and
100⁰ corners of the Insert can be utilized
Material – Gray Cast Iron
Grade- GSN-100 (GSN-100)
DOC- .13- .19 (3.3- 4.8 mm)
Speed- 4,000- 5,000 SFM (1,220- 1,525
M/Min)
Feed- .0065-.0085 (.16- .22 mm) Fd/Insert
Cut time- approx. 80 minutes per Insert
index.
A 3⁰ reverse lead cartridge is used
to circle interpolate Bores
GSN-100 Class 500
Gray Iron Milling
Class 500 Gray Iron as cast
Prior:
Seco carbide APKT 16 MM Insert
• 625 SFM (190 M/Min)
• .005 IPT (0,13 mm/tooth)
• 11 Minutes cut time
• Greenleaf ® SNGN-434 (SNGN-120416)
T2 GSN-100
• 3” Diameter C4 cutter
• 4000 SFM (1220 M/Min)
• .005 IPT (0,13 mm/tooth)
• 3 Minutes cut time
Ball Screw Housing
GSN-100 Ductile Iron
Milling
Objective: To prove out GSN-100 as a replacement
for HSN-200 in Ductile Iron Milling
We are running:
Milling Cutter – CP-403R
Nest – XFNPS-8043
Insert – SPGN-434 T2A (SPGN120416)
•
•
•
•
•
•
•
Material – Ductile Cast Iron:
Grade – HSN-200
DOC – .06” (1.52 mm) x 3
passes
Speed – 3000 SFM (915
M/Min)
Feed – .0045” (.11 mm) Actual
Chip thickness
Cutting time – 13.5 minutes
Parts – 90
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•
•
Material – Ductile Cast Iron:
Grade – GSN-100
DOC – .06” (1.52 mm) x 3
passes
Speed – 3000 SFM (915
M/Min)
Feed – .0045” (.11 mm) Actual
Chip thickness
Cutting time – 13.5 minutes
Parts – 90
GSN-100 Ductile
GGG-50 Milling
GGG-50 Milling 290-350 BHN
Other GSN-100
Applications
GSN-100 Jethete M152
Milling
Jethete M152
A 82% iron, 12% chromium material classified
as a Martensitic Stainless Steel which has high
tensile strength and sufficient ductility at
elevated temperatures as well as high corrosion
resistance. The material is very sensitive to
heat during the machining process which
makes the material rapidly work harden. The
application of Jethete M152 is mainly in high
stress gas turbine parts.
Jethete M152 32-36 R/C
Cutter: WSRP-60002 RH
Insert: RPGN-43 T1A HSN-200
Speed: 1500 SFM (458 M/Min)
Feed: .0033 IPT (.08 MM/tooth)
DOC: .050” (1.27 MM)
WOC: 2” (51 MM)
Jethete M152 32-36 R/C
Cutter: WSRP-6001.2 RH
Insert: RPGN-43 T1A HSN-200
Speed: 1600 SFM (488 M/Min)
Feed: .0015 IPT (.04 MM/tooth)
DOC: .050” (1.27 MM)
WOC: 1.25” (31.8 MM)
3 ½-4 minutes cut time, inserts
showing flank wear, and
experiencing heat in part
Jethete M152 32-36 R/C
Cutter: WSRP-6001.5 RH
Insert: RPGN-43 T1A GSN-100
Speed: 1600 SFM (488 M/Min)
Feed: .0028 IPT (.07 MM/tooth)
DOC: .050” (1.27 MM)
WOC: 1.5” (38.1 MM)
4 minutes tool life, 37 % increase in
feed over HSN-200’s best run!
GSN-100 HRSA Milling
GSN-100 42 R/C Age
Hardened Waspaloy
42 R/C age hardened Waspaloy
Cutters
Inserts
FMRN-050R
FMRN-063R
FMRN-080R
RNGN-45
T2A
FMRN-100R
FMRP-5040R
RPGN-43
FMRP-6340R
T2A
From running all the tests it is apparent that we have a safe secure
process with all sizes of cutters (both negative and positive) running
at a feed rate of 0.0027”-0.0029”, (0.07mm-0.075mm) tooth. The
surface speed is dependent on width of cut. (3000-3600 SFM/9151100 SMM range)
GSN-100
Stocking Program
GSN-100 Stocking Program
CNGN-432 T2
RPGN-2.52 T1
CNGN-433 T2
RPGN-2V T2
SNGN-433 T1A
RPGN-32 T1
SNGN-433 T2
RPGN-3V T1A
SNGN-433 T2A
RPGN-3V T2
SNGN-434 T1A
CNGN-433 T9
ACHN-3222 T1A
CNGN-434 T2
ACHN-3422 T1A
CNGN-434 T2A
CNGN-453 T1A
CNGA-432 T2
CNGA-432 T2A
CNGN-453 T2
RCGN-4V T1
RNGN-43 T2
RNGN-45 T1
CNGN-454 T1A
CNGA-433 T2
CNGN-454 T2
CNGA-434 T2
CNGN-454 T2A
CNGA-434 T3A
CNGA-453 T2
RCGN-3V T1
RNGN-45 T1A
RPGN-43 T1A
SNGN-453 T2
SNGN-454 T2
RNGN-45 T2
RNGN-45 T2A
CPGN-433 T2A
SNGN-434 T2
RPGN-43 T1
RNGN-45A
RPGN-43 T2A
RPGN-4V T2
SPGN-322 T1A
SPGN-434 T2A
CNGA-454 T2
DNGA-432 T2
SNGA-433 T2
DNGA-433 T2
SNGA-434 T2
SNGA-454 T2
TPGN-322 T2A
WG-6250-2A
WNGA-433 T2
Review
• Silicon Nitrides have their place in the high speed ceramic
machining market.
•Grades such as Greenleaf ® GSN-100 work well in interrupted
cutting and Milling operations due to Silicon Nitrides high thermal
shock resistance.
• Greenleaf ® GSN-100 works well in the machining of Gray,
Ductile, and Nodular cast irons.
• Although developed for Cast Iron machining, Greenleaf ® GSN100 works on other materials such as selected high temp alloys.
• You will want to start gearing your HSN customers to the new
Greenleaf ® GSN-100.
Questions?
Thank
You!