Transcript Document

A NEW, outstanding product to
increase your sales!
WG-300 has been the benchmark in machining
high-temp alloys and hard metals for a quarter
century.
WG-600 improved productivity by bringing the
benefits of a coated, whisker-reinforced ceramic
to industry. More speed and better tool life.
WG-700 increased output even more by combining
the advantages of an optimized new substrate with
a nano-layered coating thus improving speed, tool
life and feed rates.
Greenleaf has created a product that
will help you dominate all aspects of the
high-temp alloy business.
GREENLEAF PROUDLY INTRODUCES
SIALOX
™
Our NEWEST Ceramic MATERIAL
SIALOX
™
Is
Greenleaf’s
First Coated SiAlON
Ceramic Material!
WHAT IS A SiAlON?
• SiAlONs are a specialist class of high
temperature ceramic materials,
with high strength.
• They have high wear resistance, low thermal expansion
and good oxidation resistance.
• SiAlONs also exhibit excellent thermal shock resistance.
THERMAL SHOCK BENEFITS
One of the most important attributes of Greenleaf’s new SiAlONS is
EXCELLENT THERMAL SHOCK RESISTANCE:
This is the ability to resist cracking under conditions of rapid and
continuous thermal change.
This makes SIALOX an ideal choice in:
TM
• Interrupted Cuts
• Scale
• Milling
• Anywhere competitors SiAlONs are utilized
THERMAL SHOCK VS. WG
Thermal Shock Resistance Comparison:
• WG-300 – can withstand interrupted
cuts with thermal drop of up to 700C
without a problem. Above this micro
cracking can begin to occur leading to
failure.
• SIALOX™ – can withstand thermal
drops of 1000C+ in cuts without
degradation making it ideal for scale
and low-speed milling.
SIALOX™ C.T.O.R VS. WG
Cutting Temperature Oxidation Resistance:
• SIALOX™ – at elevated temperatures
above 1000C the material will begin to
oxidize and breakdown leading to notch
formation and failure.
• WG-300 – will continue to perform at
elevated temperatures above 1400C
with no degradation.
PROPERTIES COMPARISON
Properties of WG-300 and SIALOX™
PROPERTY
Thermal Shock
WG-300
SIALOX™
GOOD
EXCELLENT
Hardness EXCELLENT
Fracture Toughness EXCELLENT
GOOD
EXCELLENT
Strength EXCELLENT
GOOD
Oxidation Resistance EXCELLENT
GOOD
Corrosion Resistance EXCELLENT
EXCELLENT
Thermal Resistance EXCELLENT
GOOD
SIALOX™ TEST REPORTS
Greenleaf
Greenleaf Drive
Saegertown, PA 16433
(814) 763-2915
FIELD DEMONSTRATION
REPORT
Date:
Test #:
3/15/ 2012
Field testing conducted by
Greenleaf Sales & Service
Engineers
Company:
Greenleaf Rep:
Address:
Test Contact:
Tele:
TELE:
City:
Quote Contact:
Tele:
TELE:
Raouf Masrouki
Part Material: Waspaloy, 43 R/C
Insert: RPGN-4V, T1
State, Zip:
Machine:
Carnaghi Vertical
lathe
Part Name:
Case Low
Pressure Turbine
GEN-X
Operation
:
Turning
Power:
Dwg:
RPM:
Material:
Waspaloy
Hardness:
43 HRC
Condition:
Premachined
Grade: RD5025
COATED
Edge:
T1
Type of Cut:
Turning
Other:
Condition:
good
Chucking:
Coolant:
HP 250 Bars
Greenleaf
Holder:
Insert: RPGN-4V
Sandvik
CAPTO C6
RCGN-4V
CC-6060
SIALON
T01020
DEMONSTRATION OBJECTIVE:
TO TEST THE PRFORMANCE OF THE NEW R&D SIALON VS THE 6060 FROM
SANDVIK.
THE COOLANT PRESSURE IS FIXED AT 70 BARS, WE TRIED 160 BARS IN THE TEST# 3 & 4 BUT IT DOESN’T HELP
Edge:
RPM:
VC
F mm/r
m/min
200
0.5
FEED
mm/mi
25
Pass:
80
DOC:
mm
1.0
T01020
CC6060
T1
RD5025
50
DIA:
mm
1293
LC mm
42
1520
200
0.5
78
1.0
21
1
T1
RD5025
51
1560
250
0.5
50
1.0
25.5
1
T1
RD5025
50
1592
250
0.5
60
1.0
25
1
T1
RD5025
59
1620
300
0.5
15
1.0
29.5
1
T1
RD5025
53
1620
270
0.4
80
1.0
21.2
1
Remarks/Changes:
1
CHIPPING AT 5 MM FROM
THE END. GOOD RESULT
GOOD RESULT, EDGE
SIMILAR TO 6060 BUT 25%
SPEED INCREASE
FACE CHIPPING, THE
TARGET WAS 80 MM
LENGTH, BUT WE STOPPED
AT 60 MM. THE COOLANT
CHANNEL IS NOT IN THE
RIGHT DIRECTION
COOLANT 160 BARS
THE LENGTH PASS WAS 80
MM, WE REACH ONLY 15,
IMPORTANT WEAR.
COOLANT 160 BARS
GOOD RESULT, EDGE
SIMILAR TO 6060 BUT 270
m/min SPEED vs 200
Comp:Sandvik
Current parameters using
CC6060:
655 SFM (200 m/min)
019 in/rev (0.5 mm/rev)
.039 (1.0 mm) Depth of Cut
Parameters using Greenleaf SIALOX
(RD5025):
885 SFM (270 m/min)
.016 in/rev (0.4 mm/rev)
.039 (1.0 mm) Depth of Cut
Greenleaf
18695 Greenleaf Drive
Saegertown, PA 16433
(814) 763-2915
FIELD DEMONSTRATION
REPORT
Date:
Test #:
6/19/12
RD5032_INS#1&2
Company:
Greenleaf Rep:
Address:
Test Contact:
Tele:
City:
Quote Contact:
Tele:
Field testing conducted by
Greenleaf Sales & Service
Engineers
Salazar
Part Material: TELE:
Waspaloy, 43 R/C
Insert: RCGN-4V,
T1
TELE:
State, Zip:
Machine:
Okuma Howa
Power:
Part Name:
180124-1
Operation:
Present Sanvik C5
Holder:
KY1540
Dwg:
Face Turning
RPM:
800 maximum
Material:
Waspaloy
Greenleaf
Holder:
Insert: RCGN 4V
Condition:
good
Hardness:
32-44 RC
Grade: RD5032
Chucking:
Pie jaws
Condition:
Forged
Edge:
Coolant:
flood
Type of Cut:
Roughing
Other:
DEMONSTRATION OBJECTIVE:
T1
1. Evaluate in Waspaloy 2. Evaluate performance against Kennametal
1540. 3. Evaluate by increasing speed and feed by 20%
Edge:
RPM:
Present:
1.01
2.02
SUMMARY:
`
DIA.:
SFM:
IPT:
6-1/4”4”
800
.004
plunge,
.007
turn
LOC/
TIME:
DOC:
.075-.100
WOC:
parts:
Remarks/Changes:
3X, 3 indexes (1-1/2
inserts) – Plunge wall to
face, turn towards C/L to
within .100 of wall at 4”,
retract and plunge down
wall to face, machine
mismatch
6-1/4”960
.0048
.075-.100
1X - INS1, edge01& 2,
4”
plunge,
one side, insert finished
.0084
cut without failure –
turn
change to new insert
6-1/4”960
.0048
.075-.100
1X – INS2, edge01 & 02,
4”
plunge,
one side, insert finished
.0084
cut without failure –
turn
change to new insert
RD5032 inserted to evaluate with 20% increased speed and feed against KY1540 since RNGN 45
T1 RD5031 had been evaluated against KY1540 with present speed and feeds. I wanted to see as
well as show the programmer a performance difference with RD5032 over RD5031. *Kennametal
has been encouraging customer to run KY1540 as fast as 1500 SFM
Current parameters using
Kennametal KY1540:
Comp:
800 SFM (244 m/min)
007 in/rev (0.18 mm/rev) - turn
.075-.10 (1.9-2.5 mm) Depth of Cut
Parameters using Greenleaf SIALOX
(RD5032):
960 SFM (293 m/min)
.0084 in/rev (0.21 mm/rev) – turn
.075-.10 (1.9-2.5 mm) Depth of Cut
Greenleaf
FIELD TEST REPORT
Date:
Test #:
Company:
Greenleaf Rep:
Address:
Test Contact:
Tele:
City:
Quote Contact:
Tele:
7-7-2012
1C
SALAZAR
State, Zip:
Power:
Dwg:
RPM:
Material:
INCONEL 718
ROUGH TURN 2ND SIDE
INNER FLANGE FACE
Greenleaf
Present
Holder:
Holder:
RCGX35
Insert: RCGN3V
Machine:
TOSHIBA
Part Name:
Operation:
TEC
Condition:
GOOD
Hardness:
32-38 RC
Grade: RD5032
SX9
Chucking:
JAWS
Condition:
forged
Edge:
0320
Coolant:
FLOOD
Type of Cut:
ROUGH
Other:
DEMONSTRATION OBJECTIVE:
T1
EVALUATE AGAINST NTK SX9
Edge:
RPM:
DIA.:
SFM:
IPT:
Present:
64
40.542.5”
700
1.
77
2.
77
40.542.5
40.542.5
40.542.5
40.542.5
WOC:
parts:
DOC:
.012”
LOC/
TIME:
1”
840
.012”
1”
.035”
SX9 / SLOW SPEED /
CHIP RAIN / HEAVY
BURR / INCREASED
HAND FILING
INSERT 7A
840
.012”
1”
.035”
INSERT 7B
840 –
700
840700
.012”
1”
.035”
.035”
Remarks/Changes:
INSERT 8A – REDUCE
TO 100% OR 700 SFM
4.
77
.012”
1”
.035”
INSERT 8B – NET CUT /
ROUGH NOTCH /
REDUCED TO 100% OR
700 SFM
LEAD MACHINIST – INSERT LOOKED BETTER THAN SX9. BURR FROM RD5032 LESS
SUMMARY: THAN SX9 – LESS WORK TO FILE BURR.WILL DISCUSS WITH MANAGER OK TO
REPLACE SX9 WITH RD5032
3.
77
#F2421B August 29, 2011
{F2421B.doc/I:\FORMS}
Field testing conducted by
Greenleaf Sales & Service
Engineers
TELE:Inconel 718 32-38
Part Material:
TELE:
R/C
RCGN-3V, T1, SIALOX (RD5032)
700-840 SFM (213-256Comp:
m/min)
.012 in/rev (0.30 mm/rev)
.035 (0.9 mm) Depth of Cut
Customer uses WG-600 on most
applications but needed to run
slower due to part configuration
and machine. Current grade for
this part is SX9
LEAD MACHINIST said; “INSERT LOOKED
BETTER THAN SX9. BURR FROM RD5032
LESS THAN SX9 – LESS WORK TO FILE
BURR.WILL DISCUSS WITH MANAGER
OK TO REPLACE SX9 WITH RD5032”
Greenleaf
FIELD TEST REPORT
Date:
Test #:
Company:
Greenleaf Rep:
Address:
Test Contact:
Bob Schulte
Quote Contact:
City:
July 11, 2012
Mark Bachert
Tele:
TELE: 720, 40 R/C
Part Material: Udimet
TELE:
RNGN-45, A, (RD5031-uncoated)
Tele:
State, Zip:
15.140” Wheel
Machine:
Part Name:
Power: 25HP
Dwg:
RPM:
Material: Udimet720
Rough Face, Bore & Turn
Dia.
Greenleaf
Present
Holder:
Holder:
Insert
RNGN-45 RNG N-45
Operation:
Condition:
Good
Hardness: 40 Rockwell
Grade
RD5031
NS447
Chucking:
3 Jaw
Edge:
A Hone
A Hone
Coolant:
TrimSolE206
Condition: Heat Treated
Forged
Type of Cut: Rough
Test RD5031 on Udimet 720 wheel against NS 447.
SIDE ONE of 15.140” Udimet 720 Wheel
RPM:
450 SFM ( 123 m/min)
Comp:
.0045-.005 in/rev ( 0.11-0.13
mm/rev)
.075-.09 (1.9-2.5 mm) Depth of Cut
Other:
Demonstration Objective:
Edge:
Field testing conducted by
Greenleaf Sales & Service
Engineers
Parts:
DIA.:
SFM:
IPT:
LOC/ TIME:
DOC:
WOC:
Remarks/Changes:
12A-447
RD5031
15.140”
450
.0045
6 min.
.085
Small
notch
Rough Bore 2 ¼”
deep - 4 passes.
6A -447
RD5031
15.140”
450
.0045
4.25 min.
.075
Chip notch
4A – 447
RD5031
15.140”
450
.005
3.5 min.
.090
Small
notch
Semi Rough Face
Recess - 2 passes
Rough dia.of hub 1 pass
Customer currently uses NS447,
and we were able to achieve
similar results with RD5031
running at current parameters.
Present:
4.
5.
6.
SUMMARY:
RD5031 made all the rough cuts without failure. Small notching appeared on all three inserts, which
was slightly larger than on the NS447. The “A” insert showed less notching than the T1 inserts I
tested on a different Udimet 720 wheel a few weeks ago. Customer is interested in more testing on
different parts and materials. They requested a quote for 500 and 1000 pcs.
A T1 edge prep tested earlier did
not perform as well.
The new SIALOX™ which will be
coated will perform even better but
was not available for this test.
Field tests indicate there are many opportunities for increased sales!
“Mark the operator said our
grade seemed to perform better
than SX5.”
“Both RD5031 and RD5032
performed well enough for
the owner to ask for a quote.”
“Operator on the initial cuts remarked the insert
seemed to cut better. Owner asked for Greenleaf
to quote – approximate annual usage 5000+”
“RD5032 performance on
this forging performed as
well as KY1540.”
“Per operator and plant Mgr.
Insert perforated well
enough to warrant farther
testing when it becomes a
Greenleaf grade.”
PRICING AND STOCKING
Greenleaf will initially be stocking the following geometries:
RNGN 45 A
RNGN 45 T1
RCGN 3V A
RCGN 3V T1
RCGN 4V A
RCGN 4V T1
Phase 2 Stocking Program to be determined with your input.
COMPETITIVE GRADES
I
n searching for applications
for this newest grade from
Greenleaf remember to…
…Focus on these
competitors
popular grades:
Sandvik CC6060
NTK SX5
Kennametal KY1540
NTK SX9
KYS30/KYS25
SELLING VALUE: ALWAYS
“Price is what you pay. Value is what you get.”
- Warren Buffet
Value = Customer Productivity!
Greenleaf’s SIALOX™ and WG grades give your
customers the ultimate “one-two punch” in productivity!
CERAMIC GRADES RANGE
We now have a ceramic grade for just about every
circumstance:
from
GEM-7
to
GSN100
to
™
SIALOX
to
The Whisker Grades