24_A-Turning

A

Turning

General Turning Application instruction of general turning inserts

Main chip breaking range reference for general turning inserts

General turning

Application instruction of general turning inserts

Negative inserts Cutting depth(mm)

Cutting depth(mm)

DR(Double-side)

ER(Double-side)

Feed rate(mm/rev) Workpiece material: 45# steel 

Feed rate(mm/rev) Workpiece material: stainless steel (1Cr18Ni9Ti) 

Positive inserts Cutting depth(mm)

Cutting depth(mm)

Feed rate(mm/rev) Workpiece material: 45# steel 

A 22

Feed rate(mm/rev) Workpiece material: stainless steel (1Cr18Ni9Ti) 

General Turning Application instruction of general turning inserts

Turning

A

Cutting test for chip breaking range of general turning inserts

General turning

Chip breaking range

Application instruction of general turning inserts

Case Insert：CNMG120408-DF Toolholder：PCLNL2525M12 Workpiece material: #45 steel Cutting speed: 200(m/min)

A 23

WG

Chipbreaker series Turning inserts with wiper Wiper is assembled by three curves to form a circular arc edge. The Nose of wiper supply less profile highness on the surface that formed by cutting edge, so it can achieve a smooth finishing result on turning surface.

Inserts with wiper has high efficiency when used for Finish and Semi-Finish Turning. The surface quality would remain same even under double feed rate.

When used for finishing, it could improve roughness of workpiece’s surface, achieves turning instead of grinding.

When used for semi-finishing, efficiency could be improved by doubling feed rate while remaining same roughness on workpiece’s surface.

Curve

Curve

Nose of wiper

Nose of wiper

High efficiency Roughness remains same when double feed rate

Nose of normal cornor

High quality Roughness value is reduced to half when remain same feed rate.

Wiper technic = High machining efficiency + High surface quality

Guide of usage

A 24

●Choose reasonable approach angle of the tools

●Be careful with DNMX/TNMX inserts

Minor angle is closing to 0 degree is the reason of inserts with wiper could reduce roughness of surface, which is determined by shape of insert and approach angle of the toolholder. So, acceptable roughness of surface is the result of choosing reasonable approach (minor)angle.

Finishing function of wiper would be reduced or invalidated if chose unreasonable approach (Minor) Angle. For example, the approach angle should be 95o for CNMG/WNMG inserts while 93 degree is best for DNMX/TNMX inserts.

DNMX/TNMX inserts with wiper could not be generally used in applications, it can’t achieve a wiper result in which secondary approach angle are not 0 degree, like machining chamfer and profile surface, Even will cause over-cutting or nocutting on workpieces then effect the shape and size precision of workpieces. Please contact technical service stuff to solve these problems.

-EF -EM -ER

Specially designed for machining intensive adhesive and high plasticity materials like stainless steel etc

-EF Specially designed rake angle and inclined angle, it’s mainly used for machining intensively adhesive stainless steel and high plasticity materials which hard to be machined. Sharp cutting edge enables it to cutting lightly and to achieve good surface quality by well and easily control chip-breaking. It’s particularly suitable for finishing these kind materials.

-ER -EM Inserts meet the demand of machining intensively adhesive materials, Impact resistance of cutting edge is improved in base of sharpness, which makes it suitable for semi-finishing and intermittent machining adhesive materials such as austenitic stainless steel etc.

Specially designed double rake angle with wide land well balances between edge security and sharpness, and also effectively reduces cutting resistance as well as wear on groove.

Machining end surface of valve (intermittent machining) Workpiece diameter:135mm Rotating speed:350rpm Feed rate:0.25mm/r Cutting depth:1.5mm

A company Number of machined parts / Cutting edge

Machining external of valve Workpiece diameter:89mm Rotating speed:635rpm Feed rate:0.15mm/r Cutting depth:1.0mm

A company

Outside shape of valve

Number of machined parts / Cutting edge

A 25

-NF/NM

Overcome difficulties on machining Ni- base high temperature alloy

Feature of –NF/NM chipbreaker ● --NF chipbreaker has sharp cutting edge ● –NM chipbreaker has high cutting edge strength

Smooth surface of Chipbreaker leads to free flow of chip removal ● High wear resistance on cutting edge after special treatment.

Chipbreaker of inserts for machining Ni- high heat alloy is supposed to have sharp and hard edge nose, smooth rake face and reasonable inclined angle.

A 26

Characteristics of machining Ni-base high temperature alloy. ● Big cutting resistance (contains

massive alloy element, easily hardened and plastic deformation while machining) ● High temperature during cutting ● Inserts severe wear

-SF

Chipbreaker for extra-finishing

● Unique nose design and sharp cutting edge leads to small cutting resistance and

also effectively reduce vibration of the toolholder. ● High re-positioning precision on insert and is compatible with specially developed

cemented carbide toolholders, which improve the capability of vibration resistance and further improve machining quality.

● Special treatment on insert’s surface could reduce possibility of that chips are

sticking to the rake face of insert. Good performance on chip-breaking and chipflowing ensure improving on surface quality of workpieces. ● By selecting excellent grade, it’s suitable for extra finishing of various materials.

A 27

Coated Cemented Carbide CVD A 28

Golden surface is made up of TiN could reduce wear and enable to easily distinguish the variety of wear.

Special structure of Al 2O 3 deposit layer has good capability of preventing heat which strengthens the capability of substrate against plastic deformation under dry and high speed cutting condition.

TiCN layer has capability of against the abrasion which leads to best wear resistance on Flank.

By technology of gradient sintering, impact resistance on cutting edge and wear resistance are improved which finally lead to improvement of capability of cutting edge against damage.

YBC251 Coating

YBC151 The combination of substrate with excellent wear resistance and coating made up of MT-TiCN、thick layer of Al2O3 and TiN; It’s suitable for finishing steel.

Carbide with special crystal structure, improve the Red Hardness of substrate and strengthen heat resistance of insert.

YBM151 Substrate with special structure, in combination with coating made up of TiCN、 thin Al2O3 layer、 TiN, with the capability of excellent resistance against diffusive wear and plastic deformation ,which is suitable for finishing, semi-finishing and roughing of stainless steel.

YBC251 The substrate with good toughness and high security on cutting edge, in optimal combination with coating made up of MT-TiCN、thick layer of Al2O3 and TiN; It’s suitable for semi-finishing steel.

YBM251 Combination of substrate which with good toughness and strength and coating made up of TiCN, thin Al2O3 layer and TiN, the grade is suitable for semi-finishing and roughing stainless steel.

YBC351 The substrate with high strength and resistance against plastic deformation, in combination with coating made up of MT-TiCN、thick layer of Al2O3 and TiN; It’s suitable for roughing steel.

YBD151 The best combination of substrate with high wear resistance and coating made up of MT -Ti(CN)、thick Al2O3 layer and TiN, which is suitable for finishing and semi-finishing cast iron materials.

Simultaneously realizing higher cutting speed on machining steel and prolonging tool life.

Black Diamond Inserts YBC

Second generation of

YBC152

Comprising of thick TiCN and thick Al2O3 coatings, which improve the impact toughness and also abrasion resistance, is suitable for finishing and semifinishing steel at high speed. Cutting speed can increase more than 25% while the life will be improved more than 30% at the same cutting speed.

YBC252 Comprising of thick TiCN and thick Al2O3 coatings, the grade has high capability against plastic deformation and good hardness on cutting edge, and It’s preferred grade for machining steel from finishing to roughing. Under the same cutting conditions, the cutting speed can be improved more than 25% while life of tool can be 30% longer than old grade under the same cutting speed.

Roughness of inserts surface is improved after special treatment on surface, which effectively reduces cutting force, prevent workpiece adhere to surface of inserts and improve operating stability of inserts.

Before surface treatment

The perfect combination of fibrous TiCN and fine grain of Al2O3 obviously improves abrasion resistance and anti-breakage of inserts.

Al2O3

After surface treatment

Test comparison of inserts abrasion Workpiece material ：45#steel Inserts：CNMG120408-DM Cutting parameters：Vc=400m/min

ap=1mm

Grade of other company

fn=0.2mm/r

YBC152

TiCN 8min

16min

8min

16min

Coated Cemented Carbide CVD

Perfect unification of toughness and antiplastic deformation.

Specially designed on cutting edge with "skeleton" realizes perfect unification of toughness and anti-plastic deformation

Cemented carbide substrate

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First choice for high efficient and high speed machining of cast iron

Black Diamond Inserts YBD

Layer of fine grain with compact surface

● The

combination of thick coating and substrate with good hardness and impact resistance make inserts have excellent impact resistance and stability under high temperature, which improve the wear resistance of inserts while enable inserts to satisfy the requirement of high speed and big feed rate when machining cast iron.

●The appearance of shining full black is easily identified.

Significant results ●Working efficiency.has been improved,Both coating and substrate are suitable for machining cast iron under high speed and big feed rate, cutting speed can be improved 30%-40%.

Coated Cemented Carbide CVD A 30

●Saving cost, tool life can be improved about 40%-50% ●High machining stability.

YBD152 YBD052 CVD coated grade, which is combination of hard substrate and coating (extra thick Al2O3+ thick TiCN), super fine grain, smooth on surface. The grade is optimized for best wear resistance when machining gray cast iron at high speed under dry condition.

YBD102 CVD coated grade, which is combination of hard substrate and coating (thick Al2O3 + thick TiCN), shows excellent wear resistance and impact resistance when machining nodular cast iron at high speed.

CVD coated grade, which is combination of hard substrate and coating (medium thick Al2O3 + thick TiCN), good flaking resistance. It’s suitable for turning cast iron at high speed, and light intermittent cutting can be supported even under moderate speed. It’s also suitable for milling cast iron.

YBD252 CVD coated grade, which is combination of hard substrate and coating (medium thick Al2O3 + thick TiCN), well balance between wear resistance and toughness.

It’s suitable for wet milling cast iron which has toughness requirement (such as nodular cast iron) at moderate and low speed, It’s also suitable for turning under intermittent condition.

Coated Cemented Carbide CVD ■ Recommended combination of grade and chipbreaker For machining P-kind materials Grade

Type

YBC151 YBC152

DF

YBC251 YBC252

DM PM

YBC251 YBC252

DR

For machining M-kind materials Grade

For machining K-kind materials

Type

YBM151

EF EM ER

YBM251

EM ER

Grade

Type

YBD052

Without chipbreaker

YBD102

Without chipbreaker

(Double-side)

YBD152

Without chipbreaker

YBC351

DR

YBD252

Without chipbreaker

YBC351

HDR

PM PM

■ Recommended cutting parameters Workpiece material

Range of machining For finishing

P

Steel

For semi-finishing For roughing

M

Stainless steel

For finishing For semi-finishing For roughing For finishing

K

Cast iron

For semi-finishing For roughing

Grade

Recommended cutting speed(m/min)

YBC151

180-460

YBC152

220-500

YBC251

160-440

YBC252

180-480

YBC351

130-380

YBM151 YBM251

110-280

YBD052

200-500

YBD102

200-480

YBD151

180-450

YBD152

190-450

YBD252

150-380

■ Case Insert

Type

WNMG060408－PM

CNMG190616-ER

TNMA220412

Grade

YBC252

YBM151

YBD052

45#Steel HB220

Dual phase stainless steel HB260

Gray cast iron HB280

V=220m/min ap=1.5~2mm f=0.25mm/r

V=103m/min ap=1.5mm f=0.3mm/r

Vmax=400m/min ap=1.3~2.5mm f=0.4~1.1mm/r

Dry cutting

Dry cutting

Dry cutting

A company Number of machined parts/Cutting edge

A company Number of machined parts/Cutting edge

Shape of workpiece

Hardness and material of workpiece Cutting Parameters conditions Cutting fluid

Result (performance) of machining

A company Number of machined parts/Cutting edge

A 31

Coated Cemented Carbide PVD

makes it easy to machining materials which hard to be machined

New nano coating grade ● Special coating technics makes inserts smooth which leads to low friction and fluent chip flow. ● Unique coating with nano structure closely combine with substrate ensures higher hardness and toughness. ● Excellenct thermal stability and chemical stability could much effectively protect cutting edge.

YBG102 The combination of nc-TiAlN coating and fine grain substrate,It’s suitable for milling various materials (especially for cast iron) under light and medium load while also for finishing and semi-finishing turning of high temperature alloy.

nc-TiAlN coating(YBG202) Nano structure TiAlN coating with high performance guarantees good toughness and hardness of inserts. Special coating technology guarantees smooth

YBG202 Th e co mb i n a ti o n o f N C -Ti Al N c o a ti n g a n d substrate composed by ultra-fine grain,which is suitable for milling various materials with light and medium load, boring、finishing and semi-finishing turning machining of stainless steel and roughing machining of high temperature alloy.

surface and excellent wear resistance.

Outstanding thermal stability and chemical stability effectively protect cutting edge.

YBG302 The combinaton of NC-TiAlN coating and tough cemented carbide substrate, which is suitable for medium-load milling and boring of various materials, parting and grooving, semi-finishing and roughing maching of stainless steel, which is the perfect unification of security and wear resistance.

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Coated Cemented Carbide PVD ■ Recommended combination of grade and chipbreaker For machining M-kind materials

For machining S-kind materials

Grade

Type

Grade

Type

Grade

Type

YBG202

DM

YBG202

EF

YBG102

NF

YBG 302

DR HDR

YBG202

EM

YBG102

NM

General turning

For machining P-kind materials

■ Recommended cutting parameters Range of machining

Grade

Recommended cutting speed(m/min)

For finishing

YBG102

180-460

Steel

For semi-finishing

YBG202

150-380

For roughing

YBG302

130-360

M

YBG202

170-300

Stainless steel

For finishing ～for semi-finishing For roughing

YBG302

120-250

S

Heat resistant Alloy Ti alloy

For finishing

YBG102

30-90

For semi-finishing

YBG202

20-70

Workpiece material

P

■ Case Insert

Type

CNMG120404-EF

DNEG150404-NF

CNMM160612-DR

Grade

YBG202

YBG102

YBG302

Shape of workpiece

Hardness and material of workpiece Cutting conditions

Parameters

0Cr18Ni9 V=200m/min

Cutting fluid

HB240

ap=1mm

f=0.15mm/r

High temperature alloy Inconel 718 HRC≥39 Vc=80m/min

Dry cutting

B company Result (performance) of machining A company

Number of machined parts/Cutting edge

ap=0.3mm

f=0.15mm/r

30Cr1Mo1V V=100m/min

Dry cutting

ap=6mm

f=0.5mm/r

Dry cutting

B company

B company

A company

A company

Tool life (min)

HB220-260

Number of machined parts/Cutting edge

A 33

Cermet Coated Cermet The chemical stability is relatively high between Ti(CN)-base Cermet Inserts and workpiece,which reduces the friction and temperature on cutting edge during machining. Then it effectively prevents mutually diffusing of the atom of workpiece’s material and insert’s material, and significantly improves resistance to bonding abrasion. Therefore, Ti(CN)-base Cermet shows good capability of Red Hardness and resistance of crater wear, it’s a optimal material under high speed and semi-finishing maching of steel, high temperature strength of cermet is higher than that of WCCo, the toughness of cermet is better than that of Al2O3 and Si3N4 ceramic, it fulfills the application blank of WC-base cemented carbide and Al2O3 and Si3N4 ceramic between finishing and semi-finishing field at high speed.

Product feature Scientific designed structure ensures good material performance and long tool life; Aborative management on production assures the stability of product quality.

Substrate of cermet grade YNG151 (homogenized ultra-fine structure)

1

Cermet alloy with symmetrical fine grain organization and the symmetrical organization and the control of toric phase structure, improve the strength and hardness of cermet.

2

Intensified bonding phase and ingredient design of grain group, improve the cermet character of high temperature,heat conductibility and the resistance of heat and vibration.

PVD coating organization structure of cermet

3

Coating of Physical Vapour Deposition (PVD) applied to cermet substrate that with high toughness; this grade has high hardness and toughness and also with very wide application range.

■ Recommended cutting parameters Workpiece material

P

Steel

M

Stainless steel

K

Cast iron

Range of machining

For finishing

Grade

Recommended cutting speed(m/min)

YNG151

260-550

YNG151C

260-580

YNG151

170-330

YNG151C

160-350

YNG151

250-400

YNG151C

270-420

■ Case Insert: YNG151/CNMG120404-SF Hardness and material of workpiece: 20CrMnTi

B company

HB180-223 A company

Cutting parameters: v=220m/min ap=0.5~1.0mm f=0.14mm/r

Number of machined parts/Cutting edge

Chip-breaking ability is outstanding, workpiece wih good surface quality

A 34

Cemented Carbide Grade Uncoated cemented carbide grade is widely used for machining nonferrous metal, high temperature alloy etc, and it shows generality and economic character.

Substrate of YD101 – the combination of cemented carbide phase WC of fine grain and bonding phase Co.

Substrate of YD201 – the combination of cemented carbide phase WC of middling grain and bonding phase Co.

■ Recommended cutting parameters Workpiece material

Range of machining

Grade

Recommended cutting speed(m/min)

For finishing

YC10

130-360

For roughing

YC40

80-300

For finishing

YD051

100-170

For semi-finishing～ For roughing

YD201

60-130

P

Steel

K

Cast iron

N

Non-ferrous metal

For finishing ～for semi-finishing

YD101

110-

S

Heat resistant Alloy Ti alloy

For finishing

YD101

20-50

■ Case

Insert: YD101/CCGX09T304-LH Workpiece material: ZL105

HB70

Cutting parameters: v=400m/min

B company A company

ap=1mm f=0.3mm/r

Number of machined parts/Cutting edge

Workpiece has high surface quality, good precision on dimension.

A 35

Super Hardness Inserts PCBN Cubic carbon nitride

PCBN tipped inserts possess excellent hardness and thermal stability and bears 1300 degree of cutting temperature, which is mainly used for machining Hardened Steel with HRC50-60 hardness (For example: carbon tool steel, bearing steel, die steel and high speed steel and so on), gray cast iron, nodular cast iron, chilled cast iron and Ni-base、Co-base、Cr-base、Fe-base high temperature alloy.

PCD

Polycrystalline diamond

YCB011

K

PCD tipped inserts have high hardness, excellent wear resistance, low frication coefficient and good heat conductivity. It’s suitable for machining non-ferrous metals (such as Cu, Al, Mg, Ti and alloy of high-silicon aluminum etc.) and nonmetals material(such as fiberglass, ceramics and reinforced plastic etc.).

Workpiece material: cast iron Machining category: finishing

PCBN grade contains high CBN, with outstanding hardness (HV3400-3800), thermal stability, heat conductivity and good wear resistance. It’s mainly used for Machining cast iron and Fe-base P/ M materials and heat resistance alloys under high speed. Sintered cubic carbon nitride.

YCB012

H

Sintered cubic carbon nitride YCB011

Workpiece material: materials with high hardness Machining category: finishing

PCBN grade has low CBN and fine grain structure, with high hardness (HV3200-3500), good thermal conductivity and comparatively low heat conductivity. It’s mainly used for highly speed.and highly precise continuously or light intermittently Machining hardened steel (HRC45-65)

Sintered cubic carbon nitride YCB012

YCD011 N

Workpiece material: non-ferrous metal Machining category: finishing

PCD grade has medium grain structure, with high hardness(HV7000), which with outstanding wear resistance and heat conductivity, mainly suitable for high precisely machining non-ferrous metal (Al, Cu and its alloys) and Non-metals (Ceramics, Wood and reinforced Plastics etc) under high speed and high efficiency. This grade with good generality.

■ Recommended Cutting Parameters Grade

Workpiece material

Hardness

V(m/min)

f(mm/rev)

Grey cast iron Nodular cast iron Nodular cast iron Fe-base P/M Hardened steel Heat-resistant alloys Aluminum and aluminum alloys Non-metals Cemented carbide ≥15%Co

■ Case Finishing turning crosspiece Grade：YCB012 Type：CNGA120408

Tool life is improved 10%

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Material：20CrMnTi Hardness：HRC58~63 Machining mode：Dry continuous cutting Parameters：Vc=105m/min Fn=0.09mm/rev ap=0.16mm Tool life： ZCC.CT Other company CBN inserts 50pieces/edge > 45pieces/edge

S i 3N 4 s u b s t r a t e w h i c h possesses great ability against cutting edge cracking and thermal shocking. It’s suitable for finishing and semi-finishing machining grey cast iron. It also shows good performance on heavy loading and intermittent cutting of cast surface materials.

CN1000

Ceramic Grade The substrate Al2O3 + TiCN. It has high wear resistance and security on cutting edge, it’s suitable for continuously machining hardened steel and nodular cast iron.

S i 3N 4 s u b s t r a t e , i t h a s good performance both on wear resistance and t o u g h n e s s , i t ’s n o t o n l y suitable for intermittently and continuously machining hardened steel and grey cast iron, but also suitable for machining die steel and other high hardness materials.

CN2000

CA1000

■ Physical performance Grade

Hardness Hv(GPa)

Density

Bending strength

Fracture toughness

■ Recommended cutting parameters Grade

Workpiece material

Machining mode

Grey cast iron Malleable cast iron

For roughing

Cutting speed

Feed rate

Cutting depth

For finishing For roughing

Chilled cast iron Carbon steel Alloy steel Bearing steel

For finishing For roughing For finishing For roughing

Chilled steel

For semi-finishing For finishing

Grey cast iron Malleable cast iron

For roughing For finishing For roughing

Chilled cast iron

For finishing

Ni-base alloy Non-ferrous metal

For roughing For finishing

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A

Turning

General Turning Application instruction of general turning inserts

General turning

Correctional coefficient table between materials hardness and cutting speed Correctional coefficient between hardness of materials and cutting speed

Application instruction of general turning inserts

Workpiece material

P M K

Grey cast iron Nodular cast iron

N S

Theoretical Hardness

Hardness decrease

Hardness increase

-60

-40

-20

0

+20

+40

+60

+80

+100

HB180

1.42

1.24

1.11

1.0

0.91

0.84

0.77

0.72

0.67

HB180

1.44

1.25

1.11

1.0

0.91

0.84

0.78

0.73

0.68

HB220

1.21

1.13

1.06

1.0

0.95

0.90

0.86

0.82

0.79

HB250

1.33

1.21

1.09

1.0

0.91

0.84

0.75

0.70

0.65

HB75

1.05

1.0

0.95

HB350

1.12

1.0

0.89

-6

-3

0

+3

+6

+9

1.10

1.02

1.0

0.96

0.93

0.90

Rockwell hardness HRC

H

Hardness difference(Measured value – Theoretical value)

HRC60

Actual cutting speed = Recommended cutting speed×Correctional coefficient of cutting speed ・Please find recommended cutting parameters on insert packing box.

Example for using table, When the material you are going to machining is normal alloy steel, which theoretical hardness is HB180, and when the selected insert is CNMG120404-DF/YBC151, the recommended cutting speed is V=250m/min, and if the hardness measured value of the material is HB220 then the hardness difference value is 220-180=+40, correctional coefficient can be found in the table is 0.84. Therefore, the actual applicable cutting speed is Vc=250×0.84=210m/min.

Correctional coefficient table between tool life and cutting speed Correctional coefficient between tool life and cutting speed

Tool life 10 minutes

15 minutes (Standard life)

30 minutes

45 minutes

60 minutes

90 minutes

YBC151

1.12

1.00

0.82

0.73

0.67

0.60

YBC251

1.11

1.00

0.84

0.76

0.71

0.64

YBC351

1.11

1.00

0.84

0.76

0.70

0.63

YBC152

1.25

1.00

0.68

0.54

0.46

0.37

Insert materials

YBC252

1.55

1.00

0.47

0.30

0.22

0.14

YBM151

1.28

1.00

0.66

0.52

0.43

0.34

YBM251

1.19

1.00

0.75

0.63

0.56

0.47

YBG202

1.10

1.00

0.85

0.77

0.72

0.66

YBD052

1.22

1.00

0.80

0.65

0.60

0.55

YBD102

1.20

1.00

0.75

0.62

0.58

0.50

YBD151

1.20

1.00

0.74

0.63

0.55

0.47

YBD152

1.11

1.00

0.70

0.60

0.50

0.40

Actual cutting speed = Recommended cutting speed × Correctional coefficient of cutting speed

Example for using table: When the material you are going to machining is normal alloy steel, and the selected insert is CNMG120404-DF/YBC151, then the recommended cutting speed is V=250m/min(standard life is 15 minutes). If you expect the tool life to reach 60 minutes, the correctional coefficient can be found in the table is 0.67. Therefore, the actual applicable cutting speed is Vc=250×0.67=167.5m/min.

A 38