Technical Guidance Machining Exotic Alloys with CBN - SUMIBORON Edition
■ Powdered Metal
D
D
■
Cermet
Cemented Carbide
SUMIBORON
1. Flank wear
2. Surface roughness
3. Height of burr
D
■
.028 .024 .020 .016 .012 .008 .004
12
■
.020
■
D
D
10
.016
■
D
D
8
D
.012
D D
6
D D
D
.008
D
■ D D
DD
4
■ D
■ D
D D
.004
2
D D
165 330 D D ■ ■
0
0
400 660
165 330 400 660 Cutting Speed (SFM)
0
165 330 400 660 Cutting Speed (SFM)
N
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 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. c of up to 330 SFM even with cemented carbide. However, if v
■ 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 = 1,650 SFM
v c = 1,000 SFM
Notch Wear
2,000
2,000
BN7000 BNX20
1,660
1,660
Flank Wear
Flank Wear
Whisker reinforced ceramic Coated carbide (K class)
1,300
1,300
★ Influence of feed rate (Tool grade BNX20, v
c =1,000 SFM, L=0.11 miles)
1,000
1,000
f = .0047 IPR
f = . 0023 IPR
BN7000 BNX20 Whisker reinforced ceramic
660
660
330
330
Notch Wear
Flank Wear
0
0
0
1,650 3,300 4,950 6,600
0
3,275
6,500
9,850
★ Influence of tool grade ( v
c =1,650 SFM,
f =.0047 IPR. L=0.22 miles)
Cutting Length (feet)
Cutting Length (feet)
BNX20
BN7000
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
.0048
BN7000 breakage
BN7000 breakage
.008
.0040
.0040
DA150 Breakage
Carbide (K10)
Carbide (K10)
BN7000
.006
.0032
.0032
.0024
.0024
.004
DA150
DA150
.0016
.0016
.002
.0008
.0008
0
0
0
0
20 60 Cutting Time (min) 40
0
5
10 15 Cutting Time (min)
0
5
10 15 Cutting Time (min)
Part material: Ti-6A-4V Tool: NF-DNMX331 Cutting Conditions: v
Part material: Ti-6A-4V Tool: NF-DNMX331 Cutting Conditions: v
Part material: Ti-6Al-4V Tool: DNMA434 Cutting Conditions: v
c =330 SFM, f =.0019 IPR Wet ☆ Our ultra-sharp positive PCD inserts have a strong cutting edge and excellent wear resistance a p =.0039”,
c =330 SFM, f =.0019 IPR Wet ☆ Our ultra-sharp positive PCD inserts have a strong cutting edge and excellent wear resistance a p =.0039”,
c =400 SFM, 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. a p =.0118”,
■ 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
Tool Cat. No.
: SNG322
Cutting conditions : v
c =165 SFM , 1000 SFM f = .0039 IPR a p = .008” Dry
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
Made with FlippingBook Ebook Creator