Transcript The Application of WG-300

A Guide to
Selecting Ceramic Grades
Dale R. Hill
Applications Engineer
GREENLEAF CORPORATION
Saegertown, PA
Selecting Ceramic Grades
Work Materials
Nickel-Based Alloys
• Inconel
• Waspaloy
• Hastelloy
Cobalt-Based Alloys
• Stellite
• Haynes Alloys
Weld Overlays
400 and PH Series Stainless Steels (post
heat treat)
Hardened Steels (45 – 65 R/c)
Nodular and Chrome Irons
Powdered Metals
Selecting Ceramic Grades
Ceramic Tool Materials
Alumina Oxide (White Ceramic)
Alumina Oxide + TiC (Black Ceramic)
Alumina Oxide + SiC (Whiskered)
Silicon Nitride - Sialon
Selecting Ceramic Grades
Tool Application
Alumina Oxide + SiC (Whiskered) – All Materials
Alumina Oxide (White Ceramic) – Gray Cast Iron
Alumina Oxide + TiC (Black Ceramic) – Hardened Steels and Irons
Selecting Ceramic Grades
Focus Materials
Nickel-Based Alloys
• Inconel
• Waspaloy
• Hastelloy
Cobalt-Based Alloys
• Stellite
• Haynes Alloys
400 and PH Series Stainless Steels
(post heat treat)
Selecting Ceramic Grades
First Choice…
Alumina Oxide + SiC Whiskers
Greenleaf ® Grades WG-300 - WG-600 - WG-700
High Cutting Speed
Resists Catastrophic Failure
Predictable Performance
Selecting Ceramic Grades
The fracture toughness of
WG ceramics is enhanced by the
phenomenon of whisker
“pull-out”. A close examination of
the fracture surface at 3000x will
reveal not only a clear indication of
the whiskers randomly dispersed
throughout the matrix, but also the
obvious hexagonal holes where
whiskers have actually been pulled
out in the fracture process. A large
amount on energy is required to
pull the whiskers out. This greatly
enhances the fracture toughness
and thereby the high predictability
of the inserts.
Selecting Ceramic Grades
Focus Materials
Hardened Steels and Irons (45 – 65 R/c)
Weld Overlays
Selecting Ceramic Grades
Machining Hardened Materials with
Greenleaf ® Ceramic Inserts
WG Ceramics can be successfully applied to the machining of materials
other than nickel alloys. Some application areas include hardened alloy
steels, hard irons, die and mold steels, and hard weld overlays.
Common materials include : 4150, 52100, D2, A2, H13 Steels
Chilled Cast Iron, White Iron, Ni-hard, 400 Series Stainless, Weld Overlay
Selecting Ceramic Grades
In addition to WG-300, WG-600 & WG-700, Greenleaf’s GEM-7
composite ceramic has an important place in the machining of hard
materials. WG Ceramics & GEM-7 can be cost effective
alternatives to CBN in the heavy roll turning, and die & mold
industries.
GEM-7:
GEM-19:
Hot pressed Al2O3 + TiC, is used primarily for turning steels
and irons above 32 Rc. It offers high wear resistance and
moderate strength. GEM-7 can also be used on heat-resist
alloys for light finishing work.
Cold pressed and sintered Al203 offers
high abrasion wear resistance. It is
best applied in grooving operations on
gray cast irons.
Selecting Ceramic Grades
C-CDH42 T4B GEM-7 – 400 SFPM, .012 IPR @ .150” DOC
(120 m/min, 0,3 mm/rev @ 3,8 mm DOC)
Forged Steel @ 55 Hr/c
Selecting Ceramic Grades
Edge Prep for Heavy Machining
DESIGNATION
APPLICATION AREA
A
For light finishing and grooving, also added to some negative lands
B
Used in addition to heavy machining chamfers and lands
T2A
For scale cuts, light interruptions, weld overlays, turning and milling of hardened materials
T4B
Heavy machining inserts under ¾” IC (19mm), Roll turning,4V, CDH22, CDH33
T5B
Heavy machining inserts over ¾” IC (19mm), Roll turning, LNMN’s, SNGN 866’s
T7A
Similar application to T2A, use in heavier feed areas
T10B
Heavy machining inserts over ¾” IC (19mm), Roll turning in Severe Conditons, CDH43, CDH53
GEM-19 is best used on work material less than 35 Rc, while
GEM-7 works best on work materials above 35 Rc.
Selecting Ceramic Grades
C-CDH515 T4B GEM-7 – 300 SFPM, .006 IPR @ .125” DOC
(91 m/min, 0,15 mm/rev @ 3,2 mm DOC)
Forged Steel @ 62 Hr/c
Selecting Ceramic Grades
C-CDH515 T4B GEM-7 – 300 SFPM, .006 IPR @ .125” DOC
(91 m/min, 0,15 mm/rev @ 3,2 mm DOC)
Forged Steel @ 62 Hr/c
Selecting Ceramic Grades
Milling with Ceramic Tools
Focus – Hardened Materials
Selecting Ceramic Grades
Milling Hardened Materials
Recommended Grade Choice…
Alumina Oxide + Sic (Whiskers)
Greenleaf Grade WG-300 & WG-600
Selecting Ceramic Grades
Greenleaf C4, CP4 and
Excelerator milling cutters are
designed for high RPM
applications.
Excelerator®
Milling System
C-4 Series Ceramic Milling Cutters
Available in Inch or Metric diameters from
3/8 inch (10mm) to 12” (305mm).
Selecting Ceramic Grades
Greenleaf ‘s Excelerator Ball End Mill offers
the ability to use ceramic or carbide inserts
in the same cutter body.
Available in Inch or Metric Diameters…
.375” - .500” - .625” - .750” & 1.0”
10mm - 12mm - 16mm - 20mm & 25mm
Selecting Ceramic Grades
Greenleaf ® Standard Edge Preps
T1A .002 - .004” (0,05mm x 0,1mm) wide Negative Land
plus a .0005 - .001” (0,01mm – 0,02mm) Hone
T2A .006 - .008” (0,15mm x 0,2mm) wide Negative Land
plus a .0005 - .001” (0,01mm – 0,02mm) Hone
NOTE – Ceramic Ball End Mill Inserts are ‘A’ Hone only!
Selecting Ceramic Grades
C404 Cutter w / RNGN45 T2A WG-300 -- 850 SFPM, .004 IPT @ .07” DOC
(260 m/min, 0,1 mm/tooth @ 1,78 mm DOC)
P20 Tool Steel @ 55 Hr/c
Selecting Ceramic Grades
Programmed feed per tooth is affected by
chip thinning in two directions.
Radial Chip Thinning Width of Cut (WOC)
WOC
Axial Chip Thinning Depth of Cut (DOC)
DOC
Selecting Ceramic Grades
The lead angle of a round insert is variable
based on the depth of cut.
• As the depth of cut is reduced the
lead angle is increased on a round
insert.
• This will create a thinner chip,
which should be compensated for by
increasing the feed rate.
Selecting Ceramic Grades
90o Lead
Chip thickness is factored by the
width & depth of cut, and further
reduced by the lead angle.
100 % Chip Load
45o Lead
The lead angle affects a square
insert by spreading the chip out
over a longer surface.
70 % Chip Load
Selecting Ceramic Grades
•Maximum insert life can be achieved with
a step-over width of 40 – 60%.
•As the width of cut decreases, you
should increase feed to maintain
acceptable average chip thickness.
•Width and depth of cut combined with
feed rate control chip thickness.
WOC
Selecting Ceramic Grades
Internal and External Circular Interpolation
Decrease Feed
Increase Feed
Selecting Ceramic Grades
The Excelerator Milling flyer has application data & tips for Hard Milling .
Starting Speed, Feed and
Depth of Cut are based
on material hardness
and insert size.
Selecting Ceramic Grades
Classification of Greenleaf ® Ceramics
Oxide Ceramic
(White) Al2O3
GEM-19
Black
Ceramics
Al2O3 + TiC
GEM-7
Whisker
Reinforced
Ceramic
WG-300
WG-600
WG-700
Super Alloys
Hardened Steel Machining
Cast Iron Machining
Sialon
Ceramics
SIALOX
Silicon Nitride
GSN100
Guidelines to Remember
Greenleaf ® ceramic inserts can be used in a variety of high productivity
machining in a wide range of materials. The key to success is the proper
application of the principles discussed in the WG-300 Application Guide.
1. Use a toolholder system designed for ceramic inserts.
2. Use the strongest insert shape possible.
3. Use the largest corner radius possible.
4. Use the correct edge preparation for the application.
5. Use the thickest inserts available for roughing.
6. Use toolholders and bars with the largest cross section.
7. Consider heavy metal or carbide bars whenever possible.
8. Keep toolholder overhang to a minimum.
10. Rethink the process