Section N 25-26

Technical Guidance Machining Exotic Alloys with CBN - SUMIBORON Edition

■ Powdered Metal

■

Cermet

Cemented Carbide

SUMIBORON

1. Flank wear

2. Surface roughness

3. Height of burr

■

.028 .024 .020 .016 .012 .008 .004

■

.020

10 8 6 4 2

■ D

.016

.012

D D

.008

■

D D

■ D

165 330 ■ ■ D D D D

.004

400 660 D D

165 330 400 660 Cutting Speed (SFM)

Cutting Speed (SFM)

Part material: Powdered Metal (HRB40), ø3.15-ø3.94” heavy interrupted facing with grooves and drilled holes. (After 40 passes) Cutting conditions: f =.0039 IR, a p =.0039” Wet Tool Cat. No.: TNGA331

Enables cutting at v c of up to 330 SFM even with cemented carbide. However, if v c is around 400 SFM or higher, wear occurs rapidly, resulting in poorer surface roughness and greater spread of burrs. On the other hand, CBN exhibits stability and superior wear resistance, burr prevention and surface roughness, especially at high speeds.

■ Heat-Resistant Alloy ● Nickel based alloy

Typical tool damage of CBN tool when cutting Inconel 718

Cutting conditions: f = .0023 IPR, a p = .0118”, wet

Cutting conditions: f = .0047 IPR, a p = .0118”, wet

★ Influence of cutting speed (Tool grade BNX20, f =.0023 IPR, L= .45 miles) v c = 1,000 SFM v c = 1,650 SFM

Notch Wear

2,000 1,660 1,300 1,000

BN7000 BNX20

Flank Wear

Whisker reinforced ceramic Coated carbide (K class)

★ Influence of feed rate (Tool grade BNX20, v c =1,000 SFM, L=0.11 miles) f = .0047 IPR f = . 0023 IPR

BN7000 BNX20 Whisker reinforced ceramic

660 330 0

Notch Wear

Flank Wear

1,650 3,300 4,950 6,600

3,275

6,500

9,850

★ Influence of tool grade ( v c =1,650 SFM, f =.0047 IPR. L=0.22 miles) BNX20 BN7000

Cutting Length (feet)

Tool life criteria Notch wear = .010” ( ○ ) or flank wear = .010”

Tool life criteria Notch wear = .010” ( ★ ) or flank wear = .010” BN7000 is recommended for cutting at high feed rates (over f = .0039 IPR).

Notch Wear

Flank Wear

BNX20 is recommended for high speed and low feed rates; BN7000 is recommended for cutting speeds below v c = 800 SFM.

Cutting Conditions: a p = .0118”, Wet

0. 5mm

● Ti based alloy

.0048 .0040 .0032 .0024 .0016 .0008 0

BN7000 breakage

.008

DA150 Breakage

Carbide (K10)

BN7000

.006

.004

DA150

.002

20 60 Cutting Time (min) 40

5 15 Cutting Time (min) 10

Part material: Ti-6A-4V Tool: NF-DNMX331

Part material: Ti-6Al-4V Tool: DNMA434

Cutting Conditions: v c =330 SFM, a p =.0039”, f =.0019 IPR Wet ☆ Our ultra-sharp positive PCD inserts have a strong cutting edge and excellent wear resistance

Cutting Conditions: v c =400 SFM, a p =.0118”, f =.0098 IPR Wet ☆ Highly fracture-resistant BN7000 negative insert is suitable for high- efficiency machining with large depth of cut and high feed rate.

■ Hard Facing Alloys

Part Material: Colmonoy No.6

Part Material: Stellite SF-20

(NiCr-based self-fluxing alloy)

(Co-based self-fluxing alloy)

Tool Cat. No. : SNG322 Cutting conditions : v c =165 SFM , 1000 SFM f = .0039 IPR a p = .008” Dry

Tool Cat. No. : SNG322 Cutting conditions : v c = 165 SFM f = .0039 IPR a p = .008” Dry

BNS800 Competitor's Solid CBN

BNS800 (v c =1,000 SFM) Whisker reinforced ceramic (v c =165 SFM) Cutting is effectively impossible because of the large degree of wear even at v c =165

.0040

Chipping

.004 .008 .012 .016 .020

.0032

Whisker reinforced ceramic ( v c = 165 SFM, after 330 feet of cutting)

Competitor's Solid CBN (After 6,500 feet of cutting)

Chipping

.0024

.0016

.0008

Minimal wear at v c =1,000 SFM

No chipping

0 650 1,300 1,950 2,600 3,300 3,950 Cutting Distance (feet) 0

0 1,650 3,300 4,950 6,550 8,200 Cutting Distance (feet) 0

BNS800 ( v c = 1,000 SFM, after 3,300 feet of cutting)

BNS800 (After 6,500 feet of cutting)

N67

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