Materials Group

CAT.MATERIALG.9/18

Materials Group Products Sumitomo Electric Carbide, Inc.

SUMICRYSTAL

SUMIBORON PCBN

SUMIDIA WD

SUMIDIA WD

“SUMIDIA WD” is firmly bonded polycrystalline diamond developed through the use of our original ultra high-pressure sintering technology, which provides both strong and wear resistant wire drawing material.

• Characteristics SUMIDIA WD has stable quality superior to natural diamond.

Excellent breakage resistance Because of its firmly bonded polycrystalline structure, SUMIDIA WD eliminates the cleavage faults found in natural diamond.

Excellent wear-resistance SUMIDA WD offers superior wear resistance, uniform wear and excellent fracture strength.

High quality polished surface The homogeneity of sintered body is implemented in our original technology. The diamond content ratio in sintered body is increased and each diamond grain is firmly bonded. SUMIDIA WD has a high quality polished surface like natural diamond.

• Series SUMIDIA WD has 3 series such as with support ring, and with heat resistance

WD700

WD800 (Heat-Resistant type)

The WD700 series are self-supported die blanks. These blanks are suitable for all types of wiredrawing applications especially where cost-cutting is required.

The WD800 series are self-supported thermally stable blanks. These blanks are especially suited for applications which require high temperature in mounting and need high heat resistance in drawing.

WD900 The WD900 series are reinforced by a special outer ring. This feature makes it possible to draw not onlycopper and aluminum wire but high tensile steel wire as well.

• Grades

SUMIDIA WD HAS 5 GRADES: F, S, M, C, and E. • Available grades are limited by the shape and size

F

Grade

The F grade WD has a ultra fine diamond grain size. It is suitable for drawing dies that require a high quality surface finish or high fracture strength.

Strength and Wear resistance vs. Grades

2.5

2.5

S

Grade

2

2

1.5

1.5

The S grade WD has fine diamond grains. It is the standard grade of small diameter die blanks with supprt ring.

1

1

0.5

0.5

0

0

0

5 10 15 20 25 30 Grain Size(μm)

M

Grade

The M grade WD is a middle diamond grain size. It is effective for a wide variety of applications offering high finish with good wear resistance

Diamond content ratio vs. Grade

100

95

E

C

Grade

90

C

S

M

85

The C grade WD is a coarse diamond grain size. It is suitable for drawing dies that require high wear-resistance.

F

80

0

5 10 15 20 25 30

Grain Size(μm)

E

• WD800 Series

Grade

WD800 Series, binder metal removed from WD700 series, is high heat resistant material.

The E grade WD is an extra-coarse diamond grain size.

• Items

Available grain size

Dimensions ( mm)

Maximum Hole Size ( mm ) ※ 3

Concentricity ( mm ) ※ 2

Shape

ADDMA No. ※ 1

Product No.

1 3 5 12 25 F S M C E

φ d

φ D t

Self-supported die blanks

○○ ○ — ○○ ○ — ○○ ○ — ○ ○ ○ ○ ○○ ○ — ○○ ○ ○ ○○ ○ — ○○ ○ —

D6

WD705

2.5 — 1.0

0.5

D12

WD710

3.2 — 1.5

1.0

D15

WD715

5.2 — 2.5

1.5

D18

WD720

5.2 — 3.5

2.0

φ d

Self-Supported die blanks with thermal stability

t

D6

WD805

2.5 — 1.0

0.5

D12

WD810

3.2 — 1.5

1.0

D15

WD815

5.2 — 2.5

1.5

D18

WD820

5.2 — 3.5

2.0

Supported die blanks

φ D

○ ○ ○ ○ — ○ ○ ○ ○ — ○ ○ ○ ○ ○

D12

WD910

1.5 4.00 1.5

0.20

0.8

D15

WD915

4.0 8.12 2.3

0.25

1.8

D18

WD920

4.0 8.12 2.9

0.25

2.3

○ ○ ○ ○ ○ ○ ○ ○

D21

WD925

7.0 13.65 4.0

0.35

3.5

Support ring

D24

WD930

7.0 13.65 5.3

0.40

4.6

φ d

○ ○ ○ ○ ○ ○ ○ ○ ○

D27

WD940

9.0 14.50 7.5

0.40

5.4

— —

t

D27

WD945

13.0 24.13 9.0

0.33

5.8

— —

D30

WD950

13.0 24.13 12.0

0.33

7.6

— —

Standard ( WD910 ~ 950/975 ~ 995 ) φ d t

— — — ○ ○ — — — — ○ — — — — ○ — — — — ○ — — — — ○ — — — — ○ — — ○ — — ○ ○ — — — — — — — —

D33

WD960 16.0 ※ 5

24.13 16.0

0.33

10.5

D36

WD970 19.0 ※ 5

35.00 19.0

0.60

12.7

WD975 ※ 6

25.0 42.00 20.0

0.60

15.7

WD980 ※ 6

30.0 47.00 22.0

0.60

19.0 25.7 29.0

WD990 ※ 6

40.0 67.00 25.0

0.75

Press fit design ( WD960/WD970 ) φ d

WD995 ※ 6

45.0 67.00 27.0

0.75

Tungsten carbide supported die blanks with back support

WD910MW 1.5 4.00 3.5 ※ 4 ( 1.5 ) WD915MW 4.0 8.12 4.3 ※ 4 ( 2.3 ) WD920MW 4.0 8.12 4.9 ※ 4 ( 2.9 )

D12

0.20

0.8

t

0.25

1.8

D15

Back supported design ( WD910 ~ 920MW )

D18

0.25

2.3

○: Available

— : Not available

※ 1 Die size standard by American Diamond Die Manufaturers Association. ※ 2 Concentricity shows the difference between the maximum width and the minimum width of the carbide support ring. ※ 3 The maximum hole size recommended for soft wire. In case of hard wire drawing, the maximim hole size should not exeed 70 percent of this diameter. ※ 4 The number of ( ) shows tentative thickness of diamond. ※ 5 The upper diameter of diamond is different from the lower diameter. ※ 6 The blank has the inspection hole ( φ 5~8mm) in the center.

• Items

Notice in Mounting

Diamond Micro Size (A.P.S.)

Nominal Dimensions (mm)

ADDMA No. ※ 1

Shape

Product No.

Diamond Diameter ( d )

Diamond Thickness ( t )

Grain Size

WD900

WD700

WD800

1

5

12

WD910

WD940

WD995

Tungsten Carbide

SumiDisk (High Density PCD)

Method for mounting

Brazing

Heat shrinking

D6 D12 D15 D18

RX55/ 1.0 RX55/ 1.5 RX55/ 2.5 RX55/ 3.5

F F F F

M M M M

C C C C

55.0 55.0 55.0 55.0

1.0 1.5 2.5 3.5

Less than 350 ℃ Interference of shrink fit: Less than 0.05mm

Less than 600 ℃

Less than 600 ℃

Less than 900 ℃

Mounting Temperature

Diamond

φ d

t

650 ℃

850 ℃~ 1000 ℃

650 ℃

650 ℃

Allowable temperature limit

・ Do not use brazing method when mounting the Die. ・ Uniform force should be applied to the cermet ring when mounting. ・ Choose mount method when using WD900 series.

Caution

• Notice in Processing

Precaution for mounting process

Powdered brazing alloy

• Die blanks should be placed at the center of SUS case. • Die blanks should be set parallel to the case. • Do not allow space between brazing alloy and blank. (It is effective to apply pressure during heating or immediately after heating.)

Cup

Die Blank

Case

Off-center

Incline

Void

Precaution for use about shrink t type (WD960, 970).

WD960, 970 type adopt original design which PCD is pressed into support ring after sintering to avoid horizontal crack while machining. PCD diameter is different each side. (about 3%)

Large PCD diameter side : marked A

PCD

Support ring

Small PCD diameter side : marked B

・ PCD is pressed into support ring in the direction from side A to side B. Please use as Side A is Bell side, and Side B is Exit side. ・ WD960, 970 can use re-insertion to support ring when PCD slip out. ・ PCD and support ring are not combined so please keep the radial thickness of PCD more than 1.0mm.

SUMICRYSTAL

“SUMICRYSTAL” is synthetic single crystal dia- mond which Sumitomo Electric succeeded in mass production for the first time in the world. “SUMICRYSTAL” is manufactured under severe quality control has stable quality, so it is suitable for industrial materials.

Synthesis of SUMICRYSTAL

Large high quality single crystal diamonds are synthesized under ultra-high pressure (50,000 atmospheres) and high temperature (over 1,300 ℃). The figure to the right shows the inside of an ultra-high pressure apparatus. A temperature gradient is created in the interior of the heater. This gradient is used to melt the carbon source into a molten solvent metal. This process allows the diamond to grow on a seed crystal. In order to accurately synthesize large high quality crystal, it is necessary to have purity materials and advanced technology for maintaining synthesizing conditions constant over a long period of time.

The inside of an ultra-high pressure apparatus.

Sumicrystal PD dresser blanks are single crystal diamonds processed into the shape of a long, thin prism. These Sumicrystals provide high precision dress- ing through reliable performance and long tool life.

PD

PDX

Revolutionary Unique Shape The unique shape of the PD blanks gives the diamond consistent cross-section. This allows uniform diamond surface throughout the dressing process. The alongated shape also drastically reduces diamond pull-out. Characteristics

New Product with a Modified Face Orientation (1) Face orientation is a (211) face which increases life of the product (2) Abrasive resistance direction runs parallel with (111) face, facilitating setting of a blank when manufacturing dressers. Characteristics

Standard PD Items

Standard PDX Items

(mm)

(mm)

Dimensions

Dimensions

Shape

Cat.No

Shape

Cat.No

T

W L

T

W L

PD 0220

2.0~2.5 2.0~2.5 2.0~2.5 2.0~2.5 3.0~4.0 4.0~5.0

0.2± 0.05 0.2± 0.05 0.3± 0.05 0.3± 0.05 0.4± 0.05 0.4± 0.05

PDX 0220 PDX 0320 PDX 0420 PDX 0630 PDX 0640 PDX 0830 PDX 0840 PDX 1130 PDX 1140

0.2± 0.05

0.2± 0.05

PD 0230K

2.0± 0.1

PD 0420

0.4± 0.05 0.4± 0.05

PD 0440K PD 0630K PD 0640K PD 0650K PD 0830K PD 0840K PD 0850K PD 1130K PD 1140K PD 0630TK PD 0640TK PD 0830TK PD 0840TK PD 1130TK

3.0± 0.5 4.0± 0.5 3.0± 0.5 4.0± 0.5 3.0± 0.5 4.0± 0.5

0.6± 0.1

0.6± 0.1

0.6± 0.1

0.6± 0.1

5.0~

0.8± 0.1

0.8± 0.1

3.0~4.0 4.0~5.0

1.1± 0.1

1.1± 0.1

0.8± 0.1

0.8± 0.1

Can be made to order other size

5.0~

PDX crystal orientation

3.0~4.0 4.0~5.0 3.0~4.0 4.0~5.0 3.0~4.0 4.0~5.0 3.0~4.0

1.1± 0.1

1.1± 0.1

0.6± 0.1

0.6± 0.1

K Type All the above standard PDX items except PD0220, PDX0320, and PDX0420 are available in "KK Type" which both end-face lasr cuts. When ordering K Type, please include the type code (="K") after the product number. (E.g. PDX K)

0.8± 0.1

0.8± 0.1

1.1± 0.1

1.1± 0.1

Can be made to order other size

PD crystal orientation

The dresser blanks should be set to ware-resistant direction in producing the dressing using PD and PD-T

KK Type All the above standard PD items except PD0220 and PD0420 are available in "KK Type" which both end-face lasr cuts. When ordering KK Type, please include the type code (="KK") after the product number. (E.g. PD KK, PD TKK)

Sumicrystal PDXC products provide stable performance as forming dresser materials.

PDXC

(1) Proximity of highly wear-resistant (211) face to dressing face provides longer tool life. (2) Unique shape provides stable clamp strength when used as a dresser. This also prevents diamond pull-out during dressing. (3) Standardized material dimensions ensure easy setting when making dressers. Characteristics With today's ever advancing level of technology, there has been an astounding growth in the demand for ultra- precision machining processes, for machining products such as memory disks and polygon mirrors. To meet this growing need Sumitomo Electric has developed Sumicrystal UP blanks to provide the high performance and reliability required for high precision cutting tools. L (mm)

Dimensions

Cat.No

Shape

T

W L

0.8± 0.1 1.1± 0.1 1.5± 0.1 1.8± 0.1

PDXC 08

T

W

PDXC 11

2.0

2.5

PDXC 15 PDXC 18

Can be made to order other size

UP

Economy Type Economy type with which the periphery face remain unchaged. Features include large size and low cost. Standard Type Rectangular parallelopiped type surrounded by (100) faces.

Characteristics

(1) High Quality and Reliable Performance UP blanks are stable with good wear and chipping resistance. (2) Reduce Polishing to form the crystal orientation and the size of the blanks are standardized to allow easy shaping of the cutting edge.

Standard Type Items

Economy Type Items

(mm)

(mm)

Dimensions

Dimensions

Shape

Cat.No

Cat.No

Shape

L

W C1,C2 T

Ø D

T

UP 282512

1.2± 0.1

UP 2010 UP 2012 UP 2510 UP 2512 UP 2515 UP 3012 UP 3015 UP 3512 UP 3515 UP 4012 UP 4015 UP 4020 UP 4512 UP 4515 UP 4520 UP 5012 UP 5015 UP 5020

1.0 1.2 1.0 1.2 1.5 1.2 1.5 1.2 1.5 1.2 1.5 2.0 1.2 1.5 2.0 1.2 1.5 2.0

2.8~3.5 2.5~3.5 ~0.8

2

UP 282515 UP 300707 UP 301010 UP 301015 UP 301407 UP 301415 UP 301512 UP 302012

1.2± 0.1 0.7± 0.1 1.0± 0.1 1.5± 0.1 0.7± 0.1 1.5± 0.1

0.7~1.0

2.5

1.0~1.5

3.0~3.5

~0.3

1.4~1.7

3

1.5~1.8 2.0~3.0

1.2±0.1

3.5

UP 303015

1.5± 0.1

3.0~4.0

UP 333014 3.3~4.0

~0.9 1.4± 0.1

4

UP 353510 UP 353514 UP 353517 UP 351717

1.0± 0.1 1.4± 0.1

3.5~4.0

3.5~4.0

~0.4

1.7±0.1

4.5

1.7~2.0

UP 401008 3.95~4.05 0.95~1.05 ~0.5 0.75± 0.1 UP 401010 4.0~4.5 1.0~1.3 ~0.6 0.9± 1.1 UP 452417 4.5~4.8 2.4~2.7 1.7± 0.2 UP 454510 0.9± .11 UP 454515 1.5± 0.2 UP 501008 0.7± 0.2 UP 501010 0.9± 1.1 5.0~5.5 1.0~1.3 4.5~5.0 ~0.8 ~0.6 4.5~5.0

5

Can be made to order other size

Can be made to order other size

Half-cut Sumicrystal UP blanks are UP economy type blanks that have been cut in half following the (100) face or (110) face.

UP (Half cut Type)

(1) Machining loss is reduced due to the smaller volume of material removed during polishing when making tools. (2) Blank shape is close to that of a completed tool, allowing material cost savings. (3) Cut face is a smooth, lasered surface. Characteristics

Standard Items (100) Type

Standard Items (110) Type

(mm)

(mm)

Ø D T Dimensions

Ø D T Dimensions

Cat.No

Cat.No

Shape

Shape

UP 2010 (100) 1/2 UP 2012 (100) 1/2 UP 2510 (100) 1/2 UP 2512 (100) 1/2 UP 2515 (100) 1/2 UP 3010 (100) 1/2 UP 3012 (100) 1/2 UP 3015 (100) 1/2 UP 3510 (100) 1/2 UP 3512 (100) 1/2 UP 3515 (100) 1/2 UP 4010 (100) 1/2 UP 4012 (100) 1/2 UP 4015 (100) 1/2 UP 4020 (100) 1/2 UP 4510 (100) 1/2 UP 4512 (100) 1/2 UP 4515 (100) 1/2 UP 4520 (100) 1/2 UP 5010 (100) 1/2 UP 5012 (100) 1/2 UP 5015 (100) 1/2 UP 5020 (100) 1/2

UP 2010 (110) 1/2 UP 2012 (110) 1/2 UP 2510 (110) 1/2 UP 2512 (110) 1/2 UP 2515 (110) 1/2 UP 3010 (110) 1/2 UP 3012 (110) 1/2 UP 3015 (110) 1/2 UP 3510 (110) 1/2 UP 3512 (110) 1/2 UP 3515 (110) 1/2 UP 4010 (110) 1/2 UP 4012 (110) 1/2 UP 4015 (110) 1/2 UP 4020 (110) 1/2 UP 4510 (110) 1/2 UP 4512 (110) 1/2 UP 4515 (110) 1/2 UP 4520 (110) 1/2 UP 5010 (110) 1/2 UP 5012 (110) 1/2 UP 5015 (110) 1/2 UP 5020 (110) 1/2

1.0 1.2 1.0 1.2 1.5 1.0 1.2 1.5 1.0 1.2 1.5 1.0 1.2 1.5 2.0 1.0 1.2 1.5 2.0 1.0 1.2 1.5 2.0

1.0 1.2 1.0 1.2 1.5 1.0 1.2 1.5 1.0 1.2 1.5 1.0 1.2 1.5 2.0 1.0 1.2 1.5 2.0 1.0 1.2 1.5 2.0

2.0

2.0

2.5

2.5

3.0

3.0

2.5

2.5

4.0

4.0

4.5

4.5

5.0

5.0

Can be made to order other size

Can be made to order other size

Sumicrystal UPT products are tool materials that have two-point faces ((110) faces) as their main faces.

UPT

(1) Can be used as is in applications where tools would previously have been made using natural diamonds, thanks to a two-point face ((110) face) that can be used as a table face. (2) Unique shape only requires the removal of a small volume of material when used as a tool edge making efficient machining possible. Characteristics

UPT crystal Orientation

Standard Items

(mm)

Dimensions

Shape

Cat.No

T W L

UPT 3010 UPT 3012 UPT 4010 UPT 4012

0.8± 0.1 1.1± 0.1 1.5± 0.1 1.8± 0.1

3.0

2.5

4.0

3.0

Can be made to order other size

Sumicrystal CD blanks are single crystal diamond wire drawing die blanks that feature the optimum shape and crystal orientation for wire die applications. The high quality and reliability of the CD blanks provide excellent productivity.

Standard Items

(mm)

Dimensions

Shape

Cat.No

L

T

0.6± 0.1 0.8± 0.1 1.0± 0.1 1.1± 0.1 1.2± 0.1 1.4± 0.1 1.4± 0.1 1.6± 0.1 1.8± 0.1 2.0± 0.1 0.6± 0.1 1.8± 0.1 1.0± 0.1 1.1± 0.1 2.0± 0.1 1.1± 0.1 1.2± 0.1 1.4± 0.1 1.6± 0.1 2.0± 0.1

1.0± 0.1 1.0± 0.1 1.2± 0.1 1.4± 0.1 1.5± 0.1 1.5± 0.1 1.8± 0.1 2.0± 0.1 2.3± 0.1 2.5± 0.1 1.0± 0.1 1.0± 0.1 1.2± 0.1 1.4± 0.1 2.5± 0.1 1.4± 0.1 1.6± 0.1 1.8± 0.1 2.0± 0.1 2.5± 0.1

CD 1006(111) CD 1008(111) CD 1210(111) CD 1411(111) CD 1512(111) CD 1514(111) CD 1814(111) CD 2016(111) CD 2318(111) CD 2520(111)

CD

Characteristics

(1) High Quality and Reliable Performance CD blanks are a pure form of diamond, which is virutally free of impurities, inclusions and cracks that are commonly found in natural diamonds. Furthermore, the process of inspecting and selecting of crystals can be eliminated. (2) Excellent Fracture Resistance Cracking and fracturing of the diamond during wire drawing is greatly reduced. (3) Precise Crystal Orientation The top and bottom faces are in the (111) orientation and the degree of divergence in the orientation is less than 1 ° . This is a major determinate of die life. (4) Grinding is Not Necessary Because the top and bottom faces are made parallel by cleavage, further grinding is eliminated.

CD 1006R CD 1008R CD 1210R CD 1411R

CD 2520R

CD 14S CD 16S CD 18S CD 20S CD 25S

Can be made to order other size

SumiBoron is a polycrystalline cubic boron nitride cutting tool material that is comprised of a PCBN layer and cemented tungsten carbide substrate. Unlike diamond, CBN is stable under conditions of high temperature up to 1000 ° C normally seen when machining hardened ferrous, superalloy or nodular iron materials.

*Ask us about our economy type blanks

SumiBORON ® PCBN Blanks

BNX20

BNX10

BN250

BN305

BN500

BNX25

BN700

Grade

CBN Content % CBN Crystal Size (Microns A.P.S.) Primary Binder Material Vickers Hardness (Hv)

60

60

60

65

65

90-95

50

1

1

3

4

3

2

4

Titanium Nitride

Titanium Nitride

Titanium Nitride

Titanium Nitride

Titanium Nitride

Co based alloy

Titanium Nitride

3200-3400

3300

3200-3400

3500-3800

2900-3100

4000-4300

2800-3000

TRS Value (kg. / mm²)

105

125

105

105

105

125

85

· High speed continuous hardened steel finish

· Light & medium interrupted hardened steel

· Severely interrupted hardened steel

· High speed machining of bearing steel (ex. 8620)

· High speed continuous and interrupted · Wet/dry hardened steel

· Powdered metal · Ni/Co based superalloy · Ni-hard iron

· Nodular iron · Gray cast iron · Alloyed iron

Recommended for machining

SumiDIA ® DA Blanks

Grade

DA2200

DA150

DA90

0.5

5

50

Average Diamond Vickers Hardness T.R.S. (kg./mm²)

9,000-10,000

10,000-12,000

10,000-12,000

250

200

110

High Density Ultra-Fine Grain Diamond · High degree of toughness and superior wear resistance Recommended for Cutting: · Plastics · Wood · Aluminum and copper · High and low silicon aluminum

Fine Grain Diamond

Coarse Grain Diamond

Product Description

· High abrasion resistance · Excellent tool edge sharpness

· Ultra high abrasion resistance

Machining Applications · Turning

Recommended for Cutting: · High silicon aluminum · Graphite · Aluminum/gray iron bimetal · Ceramics · Tungsten carbide · Kevlar

Recommended for Cutting: · Low and medium silicon aluminum · Copper · Fiberglass · Carbon · Wood - plywood fliberboard and hardwoods

· Milling · Boring · Drilling · Sawing

Recommended Running Conditions

Material

Application Continuous

SFM

IPR

D.O.C First Choice

Second Choice

300-700 0.004-0.006 0.020" 300-700 0.004-0.006 0.020"

BNX10 BN250

Induction Hardened Steel Induction Hardened Steel Carburized Hardened Steel/ Bearing Steel Carburized Hardened Steel/ Bearing Steel Die Steel High Speed Steel Die Steel High Speed Steel Gray Cast Iron

BNX20

Interuption (Dry)

BNX25/BN305

BNX20

BNX10

Continuous

250-600 0.004-0.006 0.020"

BN250

Interuption (Dry)

0.020" 0.020" 0.020" 0.040"

BNX25/BN305

0.004-0.006 0.004-0.006 0.004-0.006 0.004-0.006

300-600

150-500 150-350 800-2300

BN250 BNX20

Continuous

BNX25/BN305 BNX10 BN700

Interuption (Dry) Continuous & Interupted Continuous & Interupted Continuous & Interupted Continuous & Interupted Continuous & Interupted

BN500

BN500

500-1500

0.004-0.006

0.040"

BN700

Nodular Cast Iron

BN500

0.040"

0.004-0.006

300-900

BN700

Ductile Iron

BN700

0.040"

0.004-0.006

400-1000

Powdered Metals

-

100-300

Chilled Cast Iron

BN250

0.040"

0.004-0.006

BN700

GLOBAL SUPPORT. GLOBAL SOLUTIONS .

Contact U.S.A. Materials Group : materialg@sumicarbide.com

Sumitomo Electric Carbide, Inc. Headquarters 1001 Business Center Drive Mount Prospect, IL  60056-2181 P.O. Box 545, Mt. Prospect, IL 60056-0545

Phone: (800) 950-5202 Phone: (847) 635-0044 Fax: (847) 635-7866 Email: materialg@sumicarbide.com

Huntsville AL Branch

Torrance CA Branch 21241 South Western Avenue Suite 120 Torrance, CA 90501 Phone: (310) 972-7118 Fax: (310) 782-0211

6700 Odyssey Drive Suite 211 Huntsville, AL 35806 Phone: (256) 971-1203 Fax: (256) 971-1205

CAT.MATERIALG.9/18

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