Technical Guidance High Speed Machining of Cast Iron with CBN - SUMIBORON Edition
■ Advantages of using CBN - SUMIBORON for cast iron machining
● Higher accuracy
● Longer tool life at higher cutting speeds
Gray Cast Iron
Ductile Cast Iron
1,650
BNS800 BN7000 BN500
BNX10
3,300
Ceramic Coated carbide Cermet
BNS800 BN7000 BNC500
BNC500
1,650
660
N
Ceramic Coated carbide Cermet
BN7000
660
Ceramic Coated carbide Cermet
↓
10 Tool Life Ratio
0.4 0.8 1.6 3.2
1
1
10
20
Good ←
Surface Roughness Standard Ra (μm)
Tool Life Ratio
■ Turning ● Cast iron structure and wear shape examples
.016
10 8 6 4 2 0
Part material
: Continuous cutting with Ductile Cast Iron
Dry Wet (water soluble)
Grey Cast Iron Ductile Cast Iron
.012
Tool material Tool Shape
: BN500
: SNG432 Cutting Conditions : v c = 1,500 SFM a p =.0098” f =.0059 IPR Dry & Wet (water soluble)
Structure
.008
.004
0
1.5 3 4.5 6 7.5
Cutting speed ( v c ) (SFM) 650
1,300
Matrix
Pearlite
Pearlite + Ferrite
Cutting Length (miles)
Wet
Machine
: N/C lathe
WET (Water soluble)
DRY
Part Material
: Ductile Cast Iron
200HB Holder
: MTJNP2525
Tool Grade Tool Shape
: BN500
: TNMA332 Cutting Conditions : v c =360 to 925 SFM f =.0039 IPR a p =.0039” Wet
Dry
Crater wear
For turning cast iron with CBN, cutting speeds ( v c ) should be 660 SFM and above. Wet cutting is recommended.
( v c =660 to 1,650 SFM)
■ Milling
BN Finish Mill EASY (for high-speed finishing of cast iron)
· Enables cutting with v c of 6,600 SFM · Surface finish roughness 3.2Rz (1.0Ra) · Economical insert reduces running costs. · Unit style enables easy runout adjustment. · Employs safe, anti-centrifugal-force construction for high-speed conditions.
250
.010
Cutting Conditions a p =.0197”, f z =.0059 IPR
Ceramic v c = 1,300 SFM
Ceramic
v c = 2000 SFM
200
.008
Dry
150
.006
v c = 3,300 SFM
v c = 2000 SFM
100
.004
Thermal cracks occur.
50
.002
v c = 5,000 SFM
Wet
1,000 0
0.0
0
Number of passes (Pass) 20 40 60 80 100 120 140 160 180 200
Cutting Speed (SFM) 1,500 2,000 2,500 3,000 3,500 4,000 4,500 5,000
Dry cutting is recommended for high speed milling of cast iron with CBN.
· Part material: Gray cast iron (FC250) · Cutting conditions: a p =.0197”, f z =.0039 IPR dry · Tool grade: BN7000
N66
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