Tungaloy-Hard_Turnin.. - OSG

Keeping the Customer FirstTungaloy Report TE0606-E5Innovative high performance cutting materialsHard turningPCBN (BX Series) and Ceramic (LX11)

Innovative high performance cutting materials“Brilliant” in Hard turningFeaturesNowadays, time consuming grindingprocesses are more and more replacedby hard turning operations. Various workpiece profiles with smallest tolerancesand different surface qualities can easilybe machined without further grinding.Furthermore, dry machining is one positiveside effect leading to reduction in productioncosts.Tungaloy is a pioneer in the productionand development of PCBN and ceramiccutting materials. Already since the early60ies and 70ies these high performancecutting grades have been produced inhouseand successfully applied in variousmachining processes. Our know-how andstate-of-the-art product research anddevelopment enable us to offer PCBN andceramic cutting materials as completeservice package to solve different machiningproblems. It is the combination ofthese two exceptional cutting materialswhich provides for highly economicmachining and effective utilisation of bothpotentials in hard turning for continuouscutting up to heavily interrupted cutting.2

Innovative high performance cutting materialsTungaloy advantages: Grade varietyPCBNPCBNGrades Micro-structure Grain size Coating ApplicationscontentBX310 45 % 5.0 µm -Suitable for high-speed continuous turning of hardened steels andother hard materials with hardness of 54 to 65 HRC.Features fine grained PCBN sintered with a special ceramic binderand especially excels in wear resistance.NEWBXC30 55 % 0.5 µm (PVD)BX330 55 % 0.5 µm -Suitable for continuous to light interrupted turning of hardenedsteels and other hard materials with hardness of 54 to 65 HRC.Features fine PCBN grain sintered with special ceramic binder andsmooth surface of newly developed PVD coated layer. Excels wearresistance and good surface roughnessSuitable for continuous to light interrupted turning of hardenedsteels and other hard materials with hardness of 54 to 65 HRC.Features fine grained PCBN sintered with a special ceramic binderand excels in wear resistance and surface roughness.NEWBX360 65 % 3.0 µm -BXC50 75 % 5.0 µm (PVD)BX380 75 % 5.0 µm -BX90S 90 % 10.0 µm -(Solid PCBN)Used for light to heavy interrupted turning of hardened steels andother hard materials with hardness of 54 to 65 HRC.Features fine to medium sized grain PCBN sintered with a specialceramic binder and excels in impact resistance.Suitable for light interrupted to heavy interrupted turning of hardenedsteels and other hard materials with hardness of 54 to 65HRC.Features medium grain sized PCBN sintered with a special binder.PCBN grade with special PVD coating layer.Used for heavy interrupted turning of hardened steels and otherhard materials with hardness of 54 to 65 HRC.Features medium grained PCBN sintered with a special ceramicbinder and excels in impact resistance.Solid PCBN surface inserts, excellent performance in roughingoperations of hardened materials from 54 to 65 HRC under difficultcutting conditions.Application at low cutting speedsNEWBXC90(Solid PCBN) 90 % 10.0 µm (PVD)PVD coated solid PCBN improved wear resistance in roughingoperations of hardened materials from 54 to 65 HRC under difficultcutting conditions.Application at low cutting speedsCutting speed Vc (m/min)300200100BXC30BX310BXC50BX330 BX360 BX380continuousheavy interruptedCutting conditions4

TungaloyHard turningMixed ceramic gradeLX11 (Ceramic)SubstrateThe homogeneous, fine-grain structure of the hard, TiN coatedceramic LX11 is based on aluminium oxide with embedded TiCN.This composition is the basis for hard turning in a wide range ofapplications at medium cutting speeds.(Vc = 120 ~ 200 m/min)Hard-soft cuttingMachining of inductive or case hardened workpieces may causeproblems for PCBN and carbide cutting materials. The coatedLX11 offers an economical alternative as workpieces with ahard-soft cutting zone can be machined in one operation.Conventional hard turningThe advantages of LX11 mainly apply at varying cutting depth(ap > 1 mm) and changing feed rates when machining complexcomponents.Cutting speed Vc (m/min)300200100LX11continuousheavy interruptedCutting conditionsCeramicGrade Micro-structureHardness(HRA)Coating ApplicationsAlumina base ceramics used for continuous turning of ferrousLX11 94 TiNhard materials.Improved strength and toughness by fining down the crystallizedparticles of alumina and titanium carbonitride.5

Hard turningLarge PCBN inlayNegativePositiveShape Item code BX330 BX360 Shape Item codeBX330 BX360CNGA120402-QBNCNGA120404-QBNCNGA120408-QBNCNGA120412-QBNCNGN090404-QBNCNGN090408-QBNDNGA150402-QBNDNGA150404-QBNDNGA150408-QBNDNGA150412-QBNDNGA150604-QBNDNGA150608-QBNDNGA150612-QBNSNGA120402-QBNSNGA120404-QBNSNGA120408-QBNSNGA120412-QBNSNGN120402-QBNSNGN120404-QBNSNGN120408-QBNSNGN120412-QBNTNGA160402-QBNTNGA160404-QBNTNGA160408-QBNTNGA160412-QBNTNGN160402-QBNTNGN160404-QBNTNGN160408-QBNTNGN160412-QBNCPGA090204-QBNCPGA090208-QBNSPGN090304-QBNSPGN090308-QBNSPGN090312-QBNSPGN120308-QBNSPGN120312-QBNTBGN060104-15-QBNTBGN060108-15-QBNTPGA090202-QBNTPGA090204-QBNTPGA110202-QBNTPGA110204-QBNTPGA110302-QBNTPGA110304-QBNTPGA160302-QBNTPGA160304-QBNTPGA160308-QBNTPGW090202-QBNTPGW090204-QBNTPGW110202-QBNTPGW110204-QBNTPGW130302-QBNTPGW130304-QBNTPGW16T302-QBNTPGW16T304-QBNTPGW16T308-QBNTPGN110304-QBNTPGN110308-QBNTPGN160304-QBNTPGN160308-QBN● Standard stock in Europe❍ Standard stock in Japan7

Innovative high performance cutting materialsMicro geometry “Potential in hard turning”Most important factor for increased productivityin modern hard turning operationsis, next to the selection of the appropriatecutting material, the surface qualityand the micro-geometrical conditions ofthe cutting edge of the insert. The relationbetween angle and length of chamferis responsible for the development ofmost different cutting forces. Flank wearand crater wear are especially provokedby the emerging passive forces. Thereforethe passive force should be as low aspossible.Tungaloy, as producer of PCBN cuttingmaterials, guarantees a complete serviceproviding the possibility of an optimaladaptation of the micro-geometry to thespecific requirements of each operation.Based on the existing standard, a 50%increase in productivity can be achievedby successfully adapting substrate andmicro-geometry to the specific demands.0.130.0525°15°RRFig. 1:Standard for negativeinserts(0.13 x 25° + R)Fig. 2:Standard for positiveinserts(0.05 x 15° + R)Influence of mikro geometry on surface qualityInterrupted cuttingContinuous cutting300150200125Tool life (%)100Tool life (min)1007500-15 -20 -25 -30 -35 -40 -15 -20 -25 -30 -35 -40Angle of chamfer (°) Angle of chamfer (°)Shaft with 2 spring slotsWork material: 34CrMo4 Vc: 100 m/minHardness: 59.4 HRC f: 0.15 mm/revap: 0.25 mmInsert: TNGN160404 Dry machiningPCBN grade: BX360Angle of chamfer: 0.13 x …+ RShaftWork material: 15CRMo5 Vc: 100 m/minHardness: 60.0 HRC f: 0.10 mm/revap: 0.25 mmInsert: TNGN160408 Dry machiningPCBN grade: BX360Angle of chamfer: 0.13 x …+ R14

Surface quality “PCBN grain size”Hard turning eliminates further grindingoperations. The required surface roughnessis often lower than Rz 3.2 µm and isdetermined by the combined action offeed rate and corner radius. In addition,the PCBN grain size of the respective cuttinggrade is another important factor.The smaller the PCBN grain is in the substrate,the higher surface qualities can beachieved. In comparison to conventional,large grain cutting materials (4 ~ 8 µm),the fine grained structure (0.5 ~ 3.5 µm)provides for a smooth and sharp cuttingedge within macro range, which excels insurface quality. This mechanical featureappears in the feed range of0.05 mm/rev and cannot be furthercompensated.PCBN grainBX330PCBN grain size: 0.5 µmBX310PCBN grain size: 5.0 µmSurface quality “Wiper”WiperStandardWiperSurface quality “Coated”The PVD-TIN carbide coating of the fine grain carbide BXC30smoothes the cutting edge in macro dimensional range. Thussurface quality of the workpiece is improved and tool life increased.Ra (µm)1.00.50Competitor coatedBX330BXC305 10Contact time (min)Work material:42CrMo4Hardness:58 HRCCutting condition:continuousInsert:CCMW09T304Vc: 150 m/minf: 0.10 mm/revap: 0.20 mm15

You want to optimize your production?Make use of our knowledge and experience!Fill in the below form and fax it through to our technicaldepartment. We will take care of your enquiry immediately.Hard turningFor one thing is true: small details create the best solutionsin hard turning.Company:Fax No:Contact person:Ref. No:MachineType: CNC conv.Description:Condition: goodmiddlebadCoolant: without withDate:MachiningTurningCutting conditions- Grooving continuous- Threading Finishing lightExternal Medium Cast / forged skinInternal Roughing heavyWork materialCodeMaterial No.Workpiece:Operation process:Manufacturer:Actual condition Test 1 Test 2 Test 3 Test 4Tool:Insert:Chipbreaker:Grade:Cutting speed:Vc (m/min)Drehzahl: n (U/min)Feed: f (mm/rev)Cutting depth: ap (mm)Output:Criteria:Pictures:16

Hard turningPractical examplesCoupling caseWork material: 16MnCr5Hardness: 60 HRCCutting condition: continuousInsert:2QP-VBMW160404Grade:BX310Vc:300 m/minf: 0.10 - 0.20 mm/revap:0.15 mmCriteria: dimensional accuracyShaftWork material: 34Mn5Hardness: 60 HRCCutting condition: continuousInsert:2QP-CCMW09T308Grade:BX330Vc:155 - 245 m/minn: 1500 min -1f: 0.10 mm/revap:0.25 mmCriteria: dimensional accuracyBevel gearWork material: 16MnCr5Hardness: 60 - 63 HRCCutting condition: continuous - heavyInsert:4QP-CNGA120408Grade:BXC50Vc:155 m/minf: 0.13 mm/revap:0.15 mmCriteria: dimensional accuracyBearing shellWork material: 100Cr6Hardness: 60 HRCCutting condition: continuousInsert:4QP-CNGA120408Grade:BXC30Vc:180 m/minf: 0.12 mm/revap:0.30 mmCriteria: dimensional accuracyShankWork material: C45Hardness: 58 HRCCutting condition: continuousInsert:2QP-DNGA150612Grade:BX330Vc:180 m/minf: 0.18 mm/revap:0.15 mmCriteria: dimensional accuracyBall bearingWork material: 100Cr6Hardness: 60 - 64 HRCCutting condition: light - forging scaleInsert:2QP-DCMW11T308Grade:BX330Vc:180 m/minf: 0.07 mm/revap:0.30 mmCriteria: roundness 0.008 mmComparison to competitor:Cutting speed increased by 50 %.Tool life by 40 %Comparison to competitor:Tool life increased by 289 %Comparison to competitor:Tool life increased by 18 %Comparison to competitor:Tool life increased by 231 %Comparison to competitor:Tool life increased by 25 %Comparison to competitor:Tool life increased by 500 %17

Hard turningTungaloy Europe GmbHElisabeth-Selbert-Str. 3D - 40764 LangenfeldTel. +49 (0 21 73) 9 04 20 -0Fax +49 (0 21 73) 9 04 20 -18e-mail: info@tungaloy.dewww.tungaloy-eu.comTungaloy Italia S.p.A.Via E. Andolfato, 10I - 20126 MILANOTel. +39 (02) 25 20 12-1Fax +39 (02) 25 20 12-65e-mail: info@tungaloy.itwww.tungaloy-eu.comTungaloy France S.a.r.l.6, Avenue des AndesF - 91952 COURTABOEUF CEDEXTel. +33 (01) 64 86 43 00Fax +33 (01) 69 07 78 17e-mail: info@tungaloy.frwww.tungaloy-eu.comDistributed by:ISO 9001 certified ISO 14001 certifiedQC00J0056 EC97J112318/10/1996 26/11/1997Tungaloy Corporation Production Division,Tungaloy CorporationTE0606-E5