New Directions in Cutting Tool Materials and Machining Options R. Wertheim, ISCAR April 2001 SH

Breakdown of World Cutting Tool Materials Shifting from HSS to Carbide Cutting Tools Other 3% PCD,CBN Ceramics Cermet 8% 4% 5% Carbide 45% HSS 35%

Worldwide Consumption of Cutting Tool Materials 1990 1995 2000 53% 50% 48% 46% 45% 35% HSS Others HSS Others Others Carbide & Cermets Carbide & Cermets Carbide & Cermets HSS 12% 6% 5%

Uncoated Carbide Grades Composition and Properties K30 K20 K10 K01 M10 M20 M30 P10 P20 P25 P30 P40 300 250 150 100 75 mT 10.0 10.5 11.0 11.5 12.0 12.5 13.0 13.5 14.0 14.5 15.5 g/cm3 Hot Hardness Wear Resistance Toughness (Magnetic Saturation) CO-Content TiC, TaC Spesific Weight ISO 513

GROUPS OF APPLICATION ® NEW ISO 513 Carbide Grades (Draft 2000) MAIN GROUPS OF APPLICATION ® GROUPS OF APPLICATION ® TOUGH CUTTING MATERIALS IDENT LETTER IDENT COLOR MATERIALS TO BE MACHINED HARD CUTTING MATERIALS P01 P10 05 P20 15 P30 25 P40 35 P50 45 P60 55 P70 65 P80 75 Steel: All kinds of steel and cast steel except stain- less steel with auste- nitic structure. 1 2 P Blue Stainless Steel: Stainless austenitic and austenitic/ferritic steel and cast steel. M10 M20 15 M30 25 M40 35 M40 M50 45 M60 55 M70 65 1 2 M Yellow K10 05 K20 15 K30 25 K40 35 K40 K50 45 K60 55 K70 65 Cast Iron: Grey cast iron, cast iron with spherodial graphite, malleable cast iron. 1 2 K Red NEW ISO 513 Carbide Grades (Draft 2000)

NEW ISO 513 Carbide Grades (Draft 2000) MAIN GROUPS OF APPLICATION ® GROUPS OF APPLICATION ® TOUGH CUTTING MATERIALS IDENT LETTER IDENT COLOR MATERIALS TO BE MACHINED HARD CUTTING MATERIALS N01 N10 05 N20 15 N30 25 N30 N40 35 N50 45 N60 55 Nonferrous Materials: Aluminum and other nonferrous metals, nonferrous materials. 1 2 N Green A or S Heavy machining Materials: Heat resistant special alloys based on iron, nickel and cobalt, tita- nium and alloys. A01 A10 05 A20 15 A30 25 A30 A40 35 A50 45 A60 55 1 2 Silver H01 H10 05 H20 15 H30 25 K40 K50 35 K60 45 K70 55 Hard Materials: Hardened steel, hardened cast iron materials, chilled cast iron. 1 2 H Brown NEW ISO 513 Carbide Grades (Draft 2000)

Uncoated Carbides Substrates for Coating 10 m m (X 2000) IC 21,Coarse WC 8% Co IC 28, Fine WC with Multi-Carbide (TaC, NbC) 12.5% Co IC 50M, Fine WC with Multi-Carbide (TiC, TaC, NbC) 11% Co

Properties of Sub-Micron Carbide Grades Compared to Cermets & Standard Carbide 19 Standard ISO 14 Fracture Toughness K1c Sub-Micron 9 Cermet 4 1200 1300 1400 1500 1600 1700 1800 1900 Hardness HV30

Uncoated Carbides Substrate Properties ISCAR GRADE DENSITY HARDNESS FRACTURE TRANSVERSE gr/cm3 HV 20KG TOUGHNESS RUPTURE K1C kg/mm STRENGTH 2 0.5 MPa (TRS) PSI X1000 IC 07 14.93 1745 11.3 520 IC 08 14.49 1580 14.8 610 IC 21 14.70 1270 19.5 450 IC 28 14.26 1340 18.0 510 IC 10 14.70 1480 13.9 450 IC 50M 12.45 1480 13.4 360 IC 20 14.96 1640 11.1 350 IC 30N 6.93 1380 10.2 260

Cermet Grades

Cermet: Composition and Grades Ceramic Binder Iscar Grade TiC Ni (1970s) TiC Ni + Mo or Mo2C IC60T, 80T, 100T TiCN Ni + Mo or Mo2C (1990s) TiCN + TaxNbyC Ni + Mo or Mo2C + Co IC30N, 20N Cermet + PVD TiN Coating IC530N, 520N (1995)

Cermet: Properties and Applications Higher hardness Higher hot hardness Lower friction Minimal BUE Better wear resistance Lower toughness (TRS) Chipping more likely Lower modulus of elasticity APPLICATIONS Higher cutting speeds Finish turning Better surface finish Small and medium chip loads Mainly continuous cutting

Surface Finish of Various Tool Materials in Turning Machining Data: Vc: 250 m/min (820 sfm) f: 0.30 mm/rev (.012”/rev) ap: 3.0 mm (.118”) Workpiece: SAE 1045 Dry, No coolant. Surface Finish, Rt (µm) 1.00 0.75 0.50 0.25 Cermet Coated Carbide Carbide

Coatings and Coated Carbide Grades

Wear Pattern of Coated Inserts Side Relief Angle Coating Rake Face Chip ap a ° b g + =90° Back Rake Angle Side Rake Flank-Face

Thermal Conductivity as a Function of Temperature 50 40 30 20 10 500 1000 1500 C° Al2O3 TiN NbC TaC TiC Temperature w m°k Thermal Conductivity

PVD and CVD: Pressure - Temperature Zones During Coating 105 104 103 102 101 100 10-1 10-2 P T °C 400 600 800 1000 1200 CVD MT-CVD PVD Plasma

Main Features of PVD and CVD Coating Proces Chemical Vapo Deposition - (CVD) Physical Vapor Deposition - (PVD) Temperature 800° - 1100° C 200° - 500°C Coating Layer Carbides, Nitrides Oxides TiN, TiCN, TiAlN Total Layer Thickness 2 - 15 mm 2 - 5 mm Features Coated on all sides More oriented coating Properties More layer combinations possible Good coating adherence Sharp cutting edge Partial adherence Less stress between substrate and coating

Indexable Inserts-World Market is Moving Towards PVD Coating Parting-Off , Grooving, Threading, Milling and Drilling Lines 1997 CVD PVD UC Cermet 55% 5% 20% 2000 CVD PVD UC Cermet 25% 8% 12% 55% 1997 CVD PVD UC Cermet 55% 5% 20% Turning is following the same trend toward PVD coatings

Cutting Tool Material Strength with PVD and CVD Coatings Uncoated CVD PVD CVD-Low Temp. Coating Thickness (TRS) mm 15 10 5 Transverse Raptne Strength (-30%) (-100-0%) (-10%)

Calculated Stress Distribution in CVD Coatings 0.200 4 0.175 1 Al2O3 2 TiC 3 TiCN 4 TiN 5 Substrate 0.150 3 0.125 1 0.100 0.075 2 Stress (xlo3Kg/mm2) 0.050 0.025 10 20 30 40 50 60 70 80 90 100 0.000 mm -0.025 5 5 -0.050 Depth Below Surface t

General Stress Distribution with PVD and CVD Coatings 5 10 Coating Substrate Depth (mm) Compression Stress Tensile Stress CVD Coating (5-10 mm) Coating Substrate Compression Stress Tensile Stress 5 10 Depth (mm) PVD Coating (2-6 mm)

CVD Coated Carbide Grades for Turning in the 1990s IC 8025 and IC 8048 Improved toughness achieved by a cobalt-enriched layer of the substrate 3rd Generation 4th Generation 3rd Generation 4th Generation IC 848 IC 825 IC 8025 IC 8048 TiN Al2O3

Basic CVD and PVD Coating Layers of ISCAR Inserts COLOR CODE Al O 2 3 TiC TiCN m TiN m IC450 X5000 (5 m) CVD IC328 X5000 ( ) PVD 2 m m 10 m IC 418 IC 450 IC 520M IC 635 IC 656 IC 220 IC 328 IC 428 IC 418 IC 228 IC 350 IC 428 IC 250 IC 3028 Turn Mill

MT-CVD Coated Structure and Properties of Basic CVD Layers TiN Al2O3 TiCN TiN Substrate Substrate: High toughness TiN: Low friction, resistance to BUE Al2O3: Heat barrier, low heat conductivity TiCN: Resistance to flank wear TiC: High hardness

The New Sub-Micron (IC 07) and PVD Coated (IC 507) Grades for Turning Substrate: 6%Co, Cr2C3,WC Coating: TiCN+TiN 3±1mm Applications: High-temp. alloys Stainless steel Hard coating Impact resistance Micro-structure of IC 07 TiN TiCN Micro-structure of IC 20 PVD coated IC 507

Sub-Micron Carbide Vs. HSS for Endmills High Toughness Low Hardness Low Rigidity Low Cutting Speed Low Heat Resistance High Toughness High Hardness High Rigidity (x 3) High Cutting Speed (x 4) High Heat Resistance Excellent Cutting-Edge Form

Standard Grain Vs. Sub-Micron Carbide Grades Sub-Micron improve hardness & toughness Standard Substrate Above 1 micron Sub-Micron Substrate Below 1 micron

New TiAlN Coating for Improved Machining Coating TiAIN 2-6m, PVD coating Properties HV 3000-3500 Excellent hot hardness Superior oxidation resistance Low thermal conductivity Sharp cutting edges Al-oxide protective layer at high temp Application Difficult-to-machine materials High speed machining Dry machining Machining of cast iron Milling and turning of Ti-alloys Machining stainless steel

TiCN Coating (IC 300) Vs. TiAIN Coating (IC 900) Hardened Tool Steel ap b Tool : Ball-Nose 12mm Material : 1.2436 (60HRC) ap : 3 mm b : 0.2 mm Speed Vc : 200 m/min Feed fz : 0.16 mm/tooth Coolant : Dry Wear Vb : 0.15 mm IC 300 = 12 m IC 900 = 24 m

PVD Processes of TiAlN Coatings Futura - up to 20 layers for indexable inserts X-Tream - for solid carbide end-mills TiAlN TiAlN TiAlN TiN Substrate Substrate

Tool Life of Solid Carbide Coated Sub-Micron Endmills VB EC TiCN ECC TiCN (300) ECC TiAIN (900) Vc: 60m/min Hardness Steel (50HRC) 0.025 0.050 0.075 0.1 mm ECC EC 500 1000 1500 2000 2500 3000 3500 4000 mm 5000 Machining Length L

Test Report - HSS Vs. Solid Carbide ae ap Machine: Victor (7.5 KW) Material : X40CrMoV5.1(1.2344) ap: 20 mm ; ae : 10 mm Coolant : Wet R 87.5 Ø200 R5 10 12.5 49• HSS Rougher ISCAR Solid Carbide Tool Grade Price net (fl) Speed Vc (m/min) Feed Vf (mm/min) Q (cm3 / min) Cycle time (sec) Tool life (pieces) Mach. costs(fl) 10 x 20 x 4Z TiCN 70 31.5 120 22 214 55 10.23 EC100B22-3W10 IC900 114.6 125 500 100 58 25 4.09 Savings per product fl. 6,16 (60%)

Impact Resistance of PVD and CVD Coated Grades in Interrupted Turning 50 60 70 80 100 (165) (204) (230) (265) (330) m/min (sfm) 200 (660) 300 (1000) 400 (1320) CVD-TiN (IC520M) Cutting Speed Vc 500 700 1000 Workpiece: SAE 4140 (980 N/mm2) Insert : SDMT 120312 (433) f : 0.2 mm/rev (.008 ipr) ap : 2.5 mm (.10 in) Dry Cutting 5000 3000 2000 7000 10000 20000 40000 Number of Impacts n PVD (IC250, IC328)

Improvement of Tool Life with Rib type Rake Face SEKR 1203-76 Improved tool life on stainless steel with -76 type and IC 328 Workpiece Material Carbide Grade Vc (sfm) Fz Tool Life TL Designation SEKR 1203 AFN-76 SEKR 1203 AFN-42 120 0.1 30’ 20’ 28’ 18’ 17-4 PH IC 328 (400) 0.1 (.004”) 17-4 PH IC 328 80 0.1 SEKR 1203 AFN-76 50’ (260) Inconel IC 328 25 0.1 (205)

New TiAlN PVD Coated Grades IC910 (K10-K25): Milling cast iron IC950 (P10-P25): Milling carbon steel, alloy steel and stainless steel; High cutting speed and dry machining IC928 (P20-P50, M20-M40, K15-K40) Alloy steel, Stainless steel IC908 (P15-P30, M20-M30, K20-K30) High temp alloys, Ni-base, Ti-base Features Hardness: HV 3000 Excellent hot hardness Sharp cutting edges Superior oxidation resistance Low thermal conductivity Al-oxide protective layer at high temp.

Comparison of Cutting Speeds Between Popular and New Grades New grades cut 20% faster or have longer tool life. MT-CVD (Al2O3) PVD( TiAlN) PVD( TiAlN) PVD (TiAlN) CVD (Al2O3) PVD ( TiCN) CVD (Al2O3) PVD( TiN) High Temp. Alloys & Stainless Steel Cast Iron GG Alloy Steels Nodular Cast Iron GGG

Tool Life in Milling SAE 1045 Steel with PVD Coatings (ISO K20 Substrate) 120 100 80 TiAIN TiCN 60 Lifetime Cutting Distance (m) 40 TiN 20 Uncoated 100 200 300 400 Cutting Speed (m/min)

Ceramics and Silicon Nitrides for Machining

Features of Ceramic Inserts High temperature hardness and toughness (hot hardness) Excellent chemical and thermal stability Suitable for machining difficult-to-cut materials and hardened steel High speed turning and milling of cast iron

Ceramics :Processing Capabilities Purchase APT Press Extrude Shape Reduce to Tungsten Trioxide and/or Tungsten metal Powder Blend, mix with carbon powder, Crush and blend Blend for uniformity and to reduce grain size Spray dry Rough machine (turn, cutoff, grind) Sinter HIP Finish grind Similar process cycle for ceramics

Cold (CIP) and Hot (HIP) Isostatic Pressing, Inertgas, Ar P= 1000 kg/cm2(15,000 psi) High density&homogeneous forming Minimum deformation during sintering Capable of producing large workpieces HIP Complete elimination of porosities Improvement of mechanical properties (strength, TRS etc ) High reliability &longer tool life

Basic Data for the Physical Properties of Ceramic Grades IN11 IN22 IN23 IS8 IS80* Compo- sition Main Elements Density (g/cm3) HV Bending Strength (MPa) Hardness HRa Al2O3 Al2O3 -TiC Si3 N4 4.0 4.3 4.2 3.2 2100 2350 2400 1700 94.2 94.5 94.6 93.6 650 700 750 1000 --- 450 550 RT 1200ºC Fracture Toughness (MN/m1.5) K 1C 4.5 5 7 Thermal Conductivity (cal/cm sec Cº) Properties of substrate

Ceramic Grades: Structure & Chemical Composition IS8 IS80 IN11 IN22 IN23 Chemical Composition Al2O3 ZrO2 Al2O3 TiC Al2O3 TiC Si3N4 Al2O3 Y2O3 Si3N4 TiN CVD Coating Color Yellow White Black Black Light Gray

SiN Tool Life in Continuous Turning Material : FC25, (Gray Cast Iron, HB180-200) Workpiece : Brake drum Insert : SNGN120416, TNGN160416 Cutting conditions Vc : 400 m/min f : 0.2-0.4 mm/rev ap : 2 - 3 mm Coolant : Wet 50 min 30 20 Tool Life Cutting Speed 200 400 10 600 m/min TNGN160416 SNGN120416 Dry Wet

Machining Directions New Cutting Tool Materials for High Speed Cutting, Dry Cutting and Hard Cutting

Main Factors Influencing High Speed Machining, Hard Cutting & Dry Cutting HSM: High-speed machining HC: Hard cutting DC: Dry cutting Insert Clamping Insert design Geometry Chipformer Balancing,Run- out Security, Safety Tool Changer Composition CBN, Cermets, Ceramics, Sub-Micron, Carbides SiN, PCD Coatings PCD, CVD CVD+PCD Properties Hardness Hot Hardness Heat Conductivity Toughness Clamping Jigs, Fixtures Composition Properties Geometry Tool Design Workpiece HSM HC DC Tool Materials Vc, ƒ,a, Z Coolant-Flushing Continuous or Interrupted Machining Conditions Machine Tool Performance Tool Clamping Stability, Vibration Spindle(Hydrostatic Mechanical) Bearing, Slides Control& Automation Tool Life Removal Rate Surface Quality Surface Integrity (Stress, Cracks, etc.) Forces, Power Machining Time

Hard Cutting with CBN Machining Non-Ferrous Materials, Al-Alloys and Composites with PCD

Manufacturing Process Optimization of the Manufacturing Process Metal Forming Casting, Forging, Powder Metallurgy, etc. Machining Rough Cutting, Non-Conventional, etc. HSM (HSC) High Speed Machining DC Dry Cutting HC Hard Cutting Heat Treatment Finishing Machining and Others Cutting Grinding Coating Finished Product

Ferrous Materials in Harder Stages for Hard Cutting White Cast Iron Hot work tool steel, cold work tool steel carbon tool steel Ball bearing steel Case hardened steel Heat-treatable steel HSS 50 55 60 65 70 Hardness due to carbide Hardness due to martensite Hardness HRc

IN22 Applications & Machining Conditions Hardened steel and difficult-to-cut material chilled cast iron, high-speed steel and high chromium steel ,etc. Recommended Cutting Conditions Workpiece Speed m/min Feed mm/rev Depth of Cut mm Chilled Cast Iron 30-200 0.05-0.2 0.1-1.5 High Speed Steel Hardened Steel (>HRc 50) 30-150 0.05-0.20 Tool Steel 100-350 0.05-0.3 1-3 Coolant Dry

High Speed Machining with Part: Mold preparation Material Nr. and Hardness: P20 mold steel - 50 - 52 HRc New IC 908 Sub-micron with TiAlN PVD coating New IC 950 Regular carbide with TiAlN PVD coating Roughing CM - D16 - B - C20 CR D160 - QF IC908 150 2 x 4 mm 3000 120 min Finishing CM - D16 - B - C20 CRF D160 - QF IC950 200 0.75 x 0.75 mm 4000 630 min Tool Insert Speed mm / min Width & Depth Revolutions / min Tool Life

Machining of Bearing Outer Ring with CUT-GRIP Turning and under cutting GHDL + CBN Inserts 2 3 1 A A

CBN, New Cutting Material for Machining Hardened Steel GITM 5.00K-2.50 GITM 5.00K-0.40 For 45-65 HRc Inserts width 3-8mm Special

Machining Synchronizing Ring with CBN CUT-GRIP Tools Machining the walls with 2 CBN inserts (Right-hand and Left-hand)

Tool Life in Finish-Turning on Hardened Steel [ WZL, T.H. Aachen] 1000 100 10 1 Super Precision High Precision Finish Turning Tool material Workpiece material PCD Copper Brass CBN Heat treated steel 54/56 HRc Austenitic stainless 85 HRb CBN/Ceramic Bearing steel 62 HRc Tool Life (Km)

Comparison of Surface Roughness & Cutting Forces in Finishing Operation [WZL, T.H. Aachen] 10 µm Surface Quality Rt 0, 1 0,01 0,001 Fc Ff Fp 1000 N Cutting forces Fc, Fƒ, Fp 10 1 0,1 Super Precision High Precision Finish Turning Tool material PCD Copper CBN Steel 56 HRc CBN Bearing steel 62 HRc Ceramic Bearing steel 62 HRc Workpiece material Feed 0,003 mm / rev 0,003 mm 0,005 mm / rev 0,005 mm 0,02 mm / rev 0,05 mm 0,08 mm / rev 0,40 mm Depth of cut

High Speed Machining H. S. M Spindle Rotation: 10,000 - 70,000 RPM

High Speed Machining (HSM)Vs Conventional Machining Speeds Reinforced Plastic Conventional Speeds HSM Range (HSC) Conventional Speeds HSM Range (HSC) Aluminum Alloys Non-ferrous materials Brass, Bronze, Copper Cast Iron Carbide Tools SiN Tools Steel Alloys Carbon & Tool Steel Titanium Alloys (Ti6Al 4V, etc.) Hardened Steel (45) 50-60 HRc Nickel Alloys (Inconel, Waspaloy) Cutting speed 1 10 100 1,000 m/min 10,000

High Performance Cutting High Speed and Feed

Super Finishing Operations with High Speed Milling Face Milling of Automotive Components Tool: F90AL-D125-3030 INT40 Insert: LNCR-1404-PDXR IC 28 High cutting speed High quality surface finish Tool with built-in pump Tool balancing option Cutting Speed: n= 8000 RPM Table Feed: Vf = 8000 mm/min Depth of cut ap= 0.8 mm Vc= 3925 m/min LNCR-1404-PDXR

Milling Cutter Design for Machining Aluminum at High Cutting Speeds

Dry and Wet Cutting

Coolant Requirements H. S. M P. C Dry Machining High Pressure

Infuence of Coolant and Chipformers on Tool Life WNMG 080408 (432) - ## CVD TiCN+TiN

Tool Life with PVD Coated Grades Coated Cermet & TiCN Coated Workpiece: SAE 1045 Vc = 260 m/min f = 0.18 mm/rev ap = 2 mm Without Coolant WNMZ 06T304(3-1)-LF Coated Cermet 0.25 (.010) 0.20 0.15 0.10 0.05 Vb mm(inch) 4’ 12’ 20’ 28’ Time 0’ 8’ 16’ 24’ TNMZ 220404(431)-LF ISO P20 TiCN Coated

Influence of Chipformers on Wear In Dry Cutting WNMG 080408 (432)-## CVD TiCN+TiN Material: SS 316L Hardness: 180HB Vc= 220m/min f= 0.25mm/rev ap= 4mm Without Coolant. Flank wear 0.052 Vb 0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 TF Notch wear Rigidity: Good PP 4 min 8

Effect of Pressurized Air Cooling on Tool Life Workpiece SAE1045 Emulsion 5% Pressurized Air cooling 120 μm 100 Flank Wear Width VB 80 60 40 20 TiN TiCN TiAIN

Flushing Option During Grooving Chip Workpiece Chip Workpiece Insert Insert Coolant Coolant Chip Chip Cutting Edge Cutting Edge Coolant Workpiece Chip Frontal Flushing Internal Flushing (Jet-Cut) Chip Insert Cutting Edge Top Flushing

Wear of Uncoated SELF-GRIP Inserts

Machingng of Inconell 718 Breakage  Grooving INCONEL 718 Number of Groove Machining conditions : Vc=30 m/min. f=0.18 mm/rev. INSERT  GFN -3 IC20  GFN -3 IC20-14 atm.  GFN -3 IC20-14 atm.  GFN -3M IC20-14 atm 0.25 0.20 0.15 0.10 0.05 1 2 3 4 5 6 7 8 9 10 Wear land VB (mm) Grooving INCONEL 718 Top (1 atm) (14 atm) JET-CUT JET-CUT+”M ” Breakage 25 100   