Transcript Slide 1

Greenleaf Carbide Profile
®
Selecting The Right Grade
Dale Hill
Applications Engineer
Technical Services
Factors Affecting Grade Choice
• Work Material?
• Operation – Milling, Turning, Etc…?
• Roughing or Finishing?
• Objective –Improve Tool Life?, Solve Breakage Problem, etc…?
• Looking for General Purpose Tool?
What Makes Grades Different?
• Amount (%)of Tungsten Carbide (Wear)
• Amount (%)of Cobalt Binder (Strength)
• Grain Size of the Powder (Wear  Strength)
• Alloying Elements - TiC (abrasion) / TaC (hot hardness)
Wear Resistance/ Hardness
Carbide Grain Size
Sub-Micron < 1µm
Fine 1-2 µm
Medium 2-3µm
Coarse 3⁺ µm
Shock Resistance/ Strength
Wear Resistance/ Hardness
Sub-Micron Grain Carbide Grades ( <1µm)
G-20M ,GA-5026, G-920, G-925
G01M, G9230
Shock Resistance/ Strength
Wear Resistance/ Hardness
Fine Grain Carbide Grades (1-2 µm)
G-40
GA-5025
G-74
Shock Resistance/ Strength
Wear Resistance/ Hardness
Medium Grain Carbide Grades (2-3µm)
G-23
G-60, GA-5125, GA-5035, G-955, G9120
G-53, GA-5036, G-935
G-10
G-02, GA-5023
Shock Resistance/ Strength
Wear Resistance/ Hardness
Coarse Grain Carbide Grades ( 3⁺µm)
G-01, GA-5040, G-910, G-915
G-50, G5135
Shock Resistance/ Strength
Wear Resistance/ Hardness
Sub-Micron < 1µm
G-20M, G-920, G-925, GA5026
G-01M , G9230
Fine Grain 1~2 µm
G40, GA5025, G74
Medium Grain 2~3 µm
G-60, GA-5125, GA-5035, G-955, G9120
G-53, GA-5036, G-935, G10, G-02, GA05023
Coarse Grain 3+ µm
G-50, G5135
G-01 , GA-5040, G-910, G-915
Shock Resistance/ Strength
TURNING
P- Steel
GA5025
GA5035(G60)
M-Stainless Steel
GA5026(G20M)
GA925(G20M)
G920(G20M)
K-Cast Iron
GA5026(G20M)
S- High Temp Alloy
GA5026(G20M)
GA925(G20M)
G920(G20M)
(except Titanium)
S-Titanium
Toughest
More Wear Resistant
G925(G20M)
G-920 (G20M)
G955(G60)
G9120 (G60)
GA5125 (G60)
G935(G53)
G5135 (G50)
G915(G01)
GA5040(G01)
GA5023(G02)
G01M
G9230 (G01M)
G915(G01)
GA5023(G02)
G5135 (G50)
G915(G01)
GA5040(G01)
GA5023 (G02)
G01M
G9230 (G01M)
G915(G01)
G925(G20M)
G01M
G9230(G01M)
G915(G01)
Basic Tool Wear Mechanisms
Flank Wear
Most Predictable Wear
Possible Solutions…
Reduce Speed
More Wear Resistant Grade
Basic Tool Wear Mechanisms
Crater Wear
Possible Solutions…
Reduce Feed
Reduce Speed
Apply Coolant
Basic Tool Wear Mechanisms
Built-up Edge
Possible Solutions…
Increase Speed
Increase Feed
Edge Prep/Hone Change
Coolant
Basic Tool Wear Mechanisms
Chipping
Possible Solutions…
Use Stronger Grade
Increase Edge Prep/Hone
Increase Tool Lead Angle
Check Tool Overhang
Check Fixture
Basic Tool Wear Mechanisms
Notching
Possible Solutions…
Change Lead Angle
Change Edge Prep/Hone
Reduce Feed
Use Ramp cutting
Basic Tool Wear Mechanisms
Thermal Cracking/ Heat Checking
Possible Solutions…
Adjust Coolant Supply
Reduce Speed
Reduce Feed
Use Higher Hot Hardness Grade
Basic Tool Wear Mechanisms
Deformation
Possible Solutions…
Reduce Speed
Reduce Feed
Coolant Flow
Select Harder Grade
Basic Tool Wear Mechanisms
Fracture
Possible Solutions…
Use Stronger Grade/Geometry
Reduce Feed
Reduce Depth of Cut
Check Tool Overhang
Check Fixture
®
The Greenleaf Carbide
Grade Profile
Carbide Grade
G-01
Uncoated Carbide
ISO Application P-M-K
Toughest Substrate
Good Choice for Turning or Milling at Low Speeds…
Stainless Steel
Low Carbon Steel
High Temperature Alloys
GA-5040
MT-CVD TiCN + TiN Coating
Carbide Base Grade - G-01
ISO Application P-M-K
Tough Substrate
Thick Layer of TiCN for
Added Abrasion Resistance
Top TiN Layer
GA-5040
Designed for Severe Use Applications
Low to Moderate Speeds
Moderate to High Feeds
Milling and Interrupted Cuts
General Purpose Grade
GA-5040
Most Economic “Go To” Grade
Questionable Machine Condition
Poor Part Fixturing
First Time Machining Material
Widest Range of Application
Spans Entire ISO “P M K” Range
G-910
PVD TiN Coated
Carbide Base Grade - G-01
ISO Application P-M-K
First Choice for Milling Titanium
Low to Medium Speeds
Medium to High Feed
Good for Higher Rake /
Sharper Edge
G-910
Application Range for ISO “P” Class Materials
Steels (Cast/Stainless), Long Chip Malleable Irons
P35 – P55
Application Range for ISO “M” Class Materials
Alloyed Cast Irons, Austenitic Stainless, Heat Resistant
M30 – M40
Application Range for ISO “K” Class Materials
Cast Iron, Nickel Alloys, Non-Ferrous Metals
K20 – K35
G-915
PVD TiAlN Coated
Carbide Base Grade - G-01
ISO Application P-M-K
Turning or Milling Grade
First Choice for Stainless Steels
Low to Medium Speeds
Medium to High Feed
G-915
Application Range for ISO “P” Class Materials
Steels (Cast/Stainless), Long Chip Malleable Irons
P35 – P55
Application Range for ISO “M” Class Materials
Alloyed Cast Irons, Austenitic Stainless, Heat Resistant
M30 – M45
Application Range for ISO “K” Class Materials
Cast Iron, Nickel Alloys, Non-Ferrous Metals
K20 – K35
Carbide Grade
G-01M
Uncoated Micro-Grain Carbide
ISO Application M-S
Tough Sub-Micron Carbide
Higher Feed and Interrupted Cuts
Cast and Forged Scale Conditions
More Wear Resistant Than G-01
Carbide Grade
G-01M
Uncoated Micro-Grain Carbide
Same ISO Range as G-01
Available in TurboForm (TF) Chipbreaker
Carbide Grade
G-9230
PVD TiAlN Coated Carbide
Carbide Base Grade - G-01M
ISO Application M-K-S
Tough Sub-Micron Carbide
Higher Feed and Interrupted Cuts
Cast and Forged Scale Conditions
Compliments Grade G-925
Carbide Grade
G-9230
PVD TiAlN Coated Carbide
ISO Application M30-K20-S20
First Choice for Medium to Heavy Machining of…
Nickel Alloys
Cobalt Alloys
Titanium Alloys Stainless Steel
Alloyed Irons
New… G-9230
Edge:
RPM:
DIA:
SFM:
Greenleaf
Greenleaf Drive
Present:
1.
IPT/
LOC/
IPR:FIELD DEMONSTRATION
TIME:
Saegertown, PA 16433
(814) 763-2915
300
WOC:
REPORT
Date:
Test #:
4”-7”Company: 350
XYZ Company.008
2.
DOC:
Parts:
001
1
.50-.150
Sean Delaney
Greenleaf Rep:
Address:
Test Contact:
Tele:
City:
Quote Contact:
Tele:
Remarks/Changes:
Insert still looked good
after 1 part
TELE:
TELE:
State, Zip:
3.
Machine:
4.
5.
Power:
Mazak Integrex
200 IIY
35 HP
Part Name:
Front Sump
Dwg:
RPM:
5,000
Material:
17-4 PH SS
Condition:
Good
Hardness:
32 Rc
Greenleaf
Holder:
Insert: CNMG 432
GP2
Grade: G9230
Chucking:
Standard 3 Jaw
Condition:
Good
Edge:
Coolant:
Yes
6.
Operation:
Type of Cut:
ID and OD
Turn
DEMONSTRATION OBJECTIVE:
Other:
Present
Holder:
Heavy
Interruption
To outperform Kennametal KC 5525
SUMMARY:
Parts:
Edge:
RPM:
DIA: with
SFM: G915
IPT/
LOC/
DOC:ranWOC:
Remarks/Changes: as above. The insert had
This insert was our second attempt.
I started
and we
the same
parameters
IPR:
TIME:
Present: so we made the change to G9230. G9230 definitely outperformed G915 in this
noticeable nose wear after 1 part
1
1.
300test4”-7”
.008
.50-.150
Insert still looked good
application. We will do an extended
with 350
this insert.
after 1 part
2.
#F241A April 22, 2004
{F2421A.doc/I:\FORMS}
3.
`
4.
5.
6.
SUMMARY:
This insert was our second attempt. I started with G915 and we ran the same parameters as above. The insert had
noticeable nose wear after 1 part so we made the change to G9230. G9230 definitely outperformed G915 in this
application. We will do an extended test with this insert.
#F241A April 22, 2004
{F2421A.doc/I:\FORMS}
`
Comp:
Carbide Grade
G-20M
Uncoated Micro-Grain Carbide
ISO Application M20-K05-S05
Sub-Micron Notch Resistant Grade
Used on High Temperature Alloys
Stands Up to Forging Scale/As Cast Materials
Carbide Grade
G-20M
Good Choice for Low Speed, Light to Medium Machining
of…
Nickel Alloys
Cobalt Alloys
Titanium Alloys
Aluminum
Non-Ferrous Material
Carbide Grade
G-920
PVD TiN Coated
Carbide Base Grade - G-20M
ISO Application M-K-S
Finish Turning Thin Walled Parts
Excellent Grooving Grade for Nickel
Based Alloys
Thermal Stability/ Low Coefficient of
Friction Reduces Built Up Edge
Machine Aluminum Alloys Instead of
“J” Polish
Carbide Grade
G-920
PVD TiN Coated
ISO Application M15-K10-S05
Alloyed Cast Irons, Stainless Steels, Heat Resistant
Available With ‘Up Sharp’ Edge
Carbide Grade
G-925
PVD TiAlN Coated
Carbide Base Grade
G-20M
ISO Application M-K-S
Higher Speeds Than G-920
TiAlN Coating Properties are
Suited for High Temperature
Cutting Conditions
Carbide Grade
G-925
PVD TiAlN Coated
ISO Application M15-K05-S05
First Choice for Light to Medium Machining of…
Titanium, Nickel and Cobalt alloys
Stainless Steels, Co-Cr-Mo and Cast Irons
Carbide Grade
G-925
PVD TiAlN Coated
Excellent Wear Grade For High Temp Alloys
2-3 Times Tool life over TiN Coated Insert
Carbide Grade
GA-5026
MT-CVD (TiCN + Al2O3 + TiN)
Carbide Base Grade
G-20M
ISO Application M-K-S
High Speed Grade
High Wear Resistance
Extended Tool Life
Carbide Grade
GA-5026
MT-CVD (TiCN + Al2O3 + TiN)
ISO Application M15-K05-S05
Higher Hot Hardness
Resistance to Cratering due to Al2O3
Light Hone Recommended
Good Steel Finishing Grade (FF2 or TF)
Carbide Grade
G-02
MT CVD ( TiCN + Al2O3)
ISO Application Range
M-K
Uncoated Grade for Cast
Iron, Aluminum, Brass,
Copper, etc.
Carbide Grade
GA-5023
MT CVD ( TiCN + Al2O3)
Carbide Base Grade
ISO Application Range
G-02
M-K
High Speed Grade
Rough and Finish Applications
Light Interrupted Cuts
Carbide Grade
GA-5023
MT CVD ( TiCN + Al2O3)
ISO Application Range M20 - K15
First Choice for Cast,
Ductile and Nodular Irons
Good Finishing Grade for Stainless (use FF2)
Carbide Grade
G-5135
MT CVD ( TiCN + Al2O3)
Carbide Base Grade
G-50
ISO Application Range P35-M30-K20
Tough Base Grade for Strength
Alumina Coating for Resistance to
Heat, Wear & Deformation
Effective against Cobalt
Enriched Grades
Carbide Grade
G-5135
Field Results Against Competition
Material
4140
life
Speed(SFM)
200-550
Feed
.015
DOC
.100
Competition
Korloy/Stellram
Result
15% better tool
4340
life
250-500
.012
.125
ZCC
12% better tool
316 Stainless Steel 200-300
life
.008
.120
Korloy/ZCC
10% better tool
410 Stainless Steel 200-250
life
.006
.100
Seco/ZCC
12% better tool
17-4 PH
200-300
.010
.075
Sumitomo/Mitsubishi
5% better tool life
Carbide Grade
G-5135
Antique to new CNC machines, out-of round parts,
Heavy Scale & Slag at a variety of speeds/feeds/doc’s
First Choice for Turning or Milling at Medium Speeds…
Forged Alloy Steel
Ductile Iron
Carbide Grade
G-5135
Current Stocking Program…
CNMG643 MR – CNMG644 MR
SNMG644 MR – SNMG866 MR
TNMG666 MR
Carbide Grade
G-53
Uncoated Carbide
ISO Application P-M
Uncoated General Purpose Steel Milling Grade
Forged/Cast Steels
400 Series Stainless Steels
Moderate Speed at Medium to High Feed
Carbide Grade
G-935
PVD - TiAlN
Carbide Base Grade
G-53
ISO Application Range
P15-P45
General Purpose Steel Milling Grade
Improved Tool Life and Speed over G-53
Deep Depth of Cut
Medium Speed at Medium to High Feed
Carbide Grade
G-60
Uncoated Carbide
ISO Application P-M
Uncoated General Purpose Steel Turning Grade
Forged/Cast Steels
400 Series Stainless Steels
Carbide Grade
GA-5035
MT CVD ( TiCN + Al2O3 + TiN)
Carbide Base Grade
ISO Application Range
G-60
P-M
All Purpose Turning Grade
for Most Steels
Good Resistance to Deformation
400 and PH Stainless Steels
Carbide Grade
GA-5035
MT CVD ( TiCN + Al2O3 + TiN)
ISO Application Range
P25 – M25
Apply at Moderate/High Speeds
Moderate Feed Rates
Carbide Grade
G-9120
PVD TiAlN Coated
Carbide Base Grade
ISO Application Range
G-60
P20-P35
Rough Turn & Mill of Steel Forgings/Castings
Moderate Speeds
Moderate to High Feeds
New… G-9120
Greenleaf
FIELD TEST REPORT
Date:
Test #:
Company:
Greenleaf Rep:
ABC Company
1-24-12
Travis Biggs
Address:
Test Contact:
Tele:
City:
Quote Contact:
Tele:
TELE:
TELE:
State, Zip:
Machine:
Ingersoll
Part Name:
Operation:
Power:
300hp
Dwg:
Greenleaf 24”mill
Holder:
Insert: 428522
RPM:
Material:
Condition:
Hardness:
P-20C
Modified
277-311 bhn
Condition:
Scale & clean
Edge:
Type of Cut:
Mill - climb
Other:
Chucking:
Coolant:
NO
DEMONSTRATION OBJECTIVE:
Mill
Present
Holder:
Grade: G9120
Testing G9120
DOC:
WOC:
parts:
.0085
LOC/
TIME:
45min
.437
18”
1/2
Chipping on cutting edge
414
.0085
45
.437
18”
414
.0085
45
.437
18”
1
Little wear/didn’t need to
index
Next part with scale and
same edge from previous
part
Edge:
RPM:
DIA.:
SFM:
IPT:
Present:
66
24”
414
1.
Clean
66
24
Scale
66
24”
Remarks/Changes:
3.
4.
5.
SUMMARY:
According to the operator he needs to index the inserts after the first cut with previous tool. With
G9120 we were able to make the entire cut and the edge was still good enough to rough the next part
that had scale.
Carbide Grade
GA5125
MT CVD ( TiCN + Al2O3)
Carbide Base Grade
ISO Application Range
G-60
P15-P30
Milling and Turning of Manganese Steels
High Speeds
Moderate Feeds
GA5125
Greenleaf
Greenleaf Drive
Saegertown, PA 16433
(814) 763-2915
Company:
FIELD DEMONSTRATION
REPORT
Date:
Test #:
Greenleaf Rep:
Greg Devine / RRM
Address:
Test Contact:
Bob
City:
Quote Contact:
XXX Rail Company
Tele:
TELE:
Tele:
TELE:
State, Zip:
IL
Machine:
MTR Mill # 2
Part Name:
Power:
50 HP
Dwg:
Switch Point
Operation:
Material:
Rail Steel
Condition:
Good
Hardness:
400 BHN
Greenleaf 14 deg mill
Holder:
Insert: SPE 55 L02 / R02
(430436 /430437)
Grade: GA5125
Chucking:
Magnetic
Condition:
Scale
Edge:
Coolant:
No
Type of Cut:
Side Mill
Other:
RPM:
DEMONSTRATION OBJECTIVE:
VR77
.004 - .006 Hone
Outperform VR Wesson & Ingersoll grades milling rail steel.
Edge:
RPM:
DIA.:
SFM:
IPM:
Present:
VR77
1.
GA5125
2.
(161)
153
212
9
(380)
360
500
(16)
13
16
9
Present
Holder:
Same
LOC/
TIME:
39 feet
DOC:
WOC:
IPT
Var
.75”
.013
39 feet
Var
.75”
.0125
Remarks/Changes:
3.
4.
5.
6.
Shop manager said this was the toughest & hardest rail steel that they run. In his experience no
SUMMARY: company had been able to run 500 SFM. (Many had tried)
The operators normally turn the feed and speed overrides down to the values listed above. We ran at 100% of our
programmed feed & speed which is significantly faster than the present parameters.
The VR Wesson or Ingersoll inserts must be indexed 3 times during this operation. We were able to complete the entire
gage cut on this switch point without indexing an insert. Only 1 insert had a small chip due to a bad screw which Greg
had marked before running our inserts. The manager was very impressed, and requested an immediate quote. Greg will
continue with further testing with the expectation that we can ran at 600 SFM with this grade.
Co
Carbide Grade
GA-5025
MT CVD ( TiCN + Al2O3+ TiN)
ISO Application Range
P
Continuous Turning
Light Interruptions
High Speeds
Low/Moderate Feeds
Carbide Grade
GA-5025
MT CVD ( TiCN + Al2O3 + TiN)
ISO Application Range
P15
Application Areas:
Tube Scarfing
Medium to Finish Turning Cast Steels
Thank You