1. Greenleaf ®
GSN-100

2. Greenleaf ® GSN-100 GSN to GSN-100 Review of Silicon Nitrides GSN-100
Description
Current data and successes
Turning
Gray Iron
Ductile Iron
Milling
Other applications
GSN-100 vs. HSN-100 & 200

3. Silicon Nitrides Greenleaf ® GSN-100
Developed for Cast Iron Applications
Higher thermal shock resistance when compared to Whisker Ceramics
Lower high temperature stability compared to Whisker Ceramics
Best in interrupted cutting due to high thermal shock resistance
Scale
Milling

4. Greenleaf ® GSN-100
An engineered blend of silicon nitride and proprietary toughening agents that redefine productivity in the machining of cast iron.
GSN100 delivers outstanding tool life at high cutting speeds in turning, grooving and milling applications.

5. GSN-100 Test Data

6. GSN-100 Class 30 Gray Iron Turning

7. Gray Cast Iron, class 30, 20 R/C
Competitor: GC-4187 K40C
2000 SFM (610 M/Min)
.004 IPR plunge (0,10 mm/rev)
.008 IPR turn (0,20 mm/rev)
Greenleaf ® WG A SG-0173
4000 SFM (1220 M/Min)
.008 IPR plunge (0,20 mm/rev)
.012 IPR turn (0,30 mm/rev) 7

8. Gray Cast Iron, class 30, 20 R/C
This customer presently running competitor GC-4187 K40C grade and completing 15 parts per insert with a cycle time of minutes.
Ran test with WG A GSN-100 insert and completed 74 parts per insert
Cycle time minutes
5X greater tool life
SFM is 2X present tool
Feed rate is 4X present tool.
Inserts ran parts for 3+ days before needing changed.

9. GSN-100 Class 435 Gray Iron Turning

10. Round 1 testing The areas of focus for testing were:
Tool #1 Back Face and Rough Pilot
Area of focus
Customer target: 150 parts per edge

11. Tool #1 - Back Face and Rough Pilot
Round 1 testing
Tool #1 - Back Face and Rough Pilot
Customer target: 150 parts per edge

12. $240,554 total yearly savings

13. Round 2 testing The areas of focus for testing were:
Tool #3 – Inboard Bottom Face.
Tool #6 – Finish Pilot
Tool #6
Tool #3
Customer target: 300 parts per edge

14. Tool #3 – Inboard Bottom Face.
Round 2 testing
Tool #3 – Inboard Bottom Face.
Customer target: 300 parts per edge

15. $112,970 total yearly savings

16. Round 2 testing Tool #6 – Finish Pilot.
Customer target: 300 parts per edge

17. $112,970 total yearly savings

18. GSN-100 Ductile Iron Turning

19. 65-45-12 Ductile Iron, 30 R/C 5X tool life over HSN-100
Prior: Greenleaf WG A
HSN-100
1350 SFM (412 M/Min)
.0065 IPT (0,17 mm/tooth)
Machining 15 grooves/insert
Greenleaf WG A
GSN-100
1350 SFM (412 M/Min)
.0065 IPT (0,17 mm/tooth)
Machining 75 grooves/insert
5X tool life over HSN-100

20. GSN-100 Cast Iron Milling

21. Gray Cast Iron, as cast We are running: Milling Cutter- C404
Insert- CNGN-454 (CNGN120716)
Two Nests are used so both the 80⁰ and
100⁰ corners of the Insert can be utilized
Material – Gray Cast Iron
Grade- GSN-100 (GSN-100)
DOC ( mm)
Speed- 4,000- 5,000 SFM (1,220- 1,525 M/Min)
Feed ( mm) Fd/Insert
Cut time- approx. 80 minutes per Insert index.
A 3⁰ reverse lead cartridge is used
to circle interpolate Bores

22. GSN-100 Class 500 Gray Iron Milling

23. Class 500 Gray Iron as cast 73% reduction in cut time
Ball Screw Housing
Prior:
Seco carbide APKT 16 MM Insert
625 SFM (190 M/Min)
.005 IPT (0,13 mm/tooth)
11 Minutes cut time
Greenleaf SNGN-434 (SNGN ) T2 GSN-100
3” Diameter C4 cutter
4000 SFM (1220 M/Min)
.005 IPT (0,13 mm/tooth)
3 Minutes cut time
73% reduction in cut time

24. GSN-100 Ductile Iron Milling

25. Insert – SPGN-434 T2A (SPGN120416)
Objective: To prove out GSN-100 as a replacement for HSN-200 in Ductile Iron Milling
We are running:
Milling Cutter – CP-403R
Nest – XFNPS-8043
Insert – SPGN-434 T2A (SPGN120416)
Material – Ductile Cast Iron:
Grade – HSN-200
DOC – .06” (1.52 mm) x 3 passes
Speed – 3000 SFM (915 M/Min)
Feed – .0045” (.11 mm) Actual Chip thickness
Cutting time – 13.5 minutes
Parts – 90
Material – Ductile Cast Iron:
Grade – GSN-100
DOC – .06” (1.52 mm) x 3 passes
Speed – 3000 SFM (915 M/Min)
Feed – .0045” (.11 mm) Actual Chip thickness
Cutting time – 13.5 minutes
Parts – 90

26. GSN-100 Ductile
GGG-50 Milling

28. GGG-50 Milling BHN

29. Other GSN-100
Applications

30. GSN-100 Jethete M152 Milling

31. Jethete M152
A 82% iron, 12% chromium material classified as a Martensitic Stainless Steel which has high tensile strength and sufficient ductility at elevated temperatures as well as high corrosion resistance. The material is very sensitive to heat during the machining process which makes the material rapidly work harden. The application of Jethete M152 is mainly in high stress gas turbine parts.

32. Jethete M152 32-36 R/C 2 minutes cut time, inserts burned,
Cutter: WSRP RH
Insert: RPGN-43 T1A HSN-200
Speed: 1500 SFM (458 M/Min)
Feed: IPT (.08 MM/tooth)
DOC: .050” (1.27 MM)
WOC: 2” (51 MM)
2 minutes cut time, inserts burned,
show flank wear, have deformation,
and built up edge. 32

33. Jethete M152 32-36 R/C Cutter: WSRP-6001.2 RH
Insert: RPGN-43 T1A HSN-200
Speed: 1600 SFM (488 M/Min)
Feed: IPT (.04 MM/tooth)
DOC: .050” (1.27 MM)
WOC: 1.25” (31.8 MM)
3 ½-4 minutes cut time, inserts showing flank wear, and experiencing heat in part 33

34. 4 minutes tool life, 37 % increase in feed over HSN-200’s best run!
Jethete M R/C
Cutter: WSRP RH
Insert: RPGN-43 T1A GSN-100
Speed: 1600 SFM (488 M/Min)
Feed: IPT (.07 MM/tooth)
DOC: .050” (1.27 MM)
WOC: 1.5” (38.1 MM)
4 minutes tool life, 37 % increase in feed over HSN-200’s best run! 34

35. GSN-100 HRSA Milling

36. GSN-100 42 R/C Age Hardened Waspaloy

37. 42 R/C age hardened Waspaloy
Cutters Inserts
FMRN-050R
FMRN-063R RNGN-45
FMRN-080R T2A
FMRN-100R
FMRP-5040R RPGN-43
FMRP-6340R T2A
From running all the tests it is apparent that we have a safe secure process with all sizes of cutters (both negative and positive) running at a feed rate of ” ”, (0.07mm-0.075mm) tooth. The surface speed is dependent on width of cut. ( SFM/ SMM range)

38. GSN-100
Stocking Program

39. GSN-100 Stocking Program CNGN-432 T2 CNGN-433 T2 CNGN-433 T9
CNGN-434 T2A
CNGN-453 T1A
CNGN-453 T2
CNGN-454 T1A
CNGN-454 T2
CNGN-454 T2A
CPGN-433 T2A
DNGA-432 T2
DNGA-433 T2
RPGN-2.52 T1
RPGN-2V T2
RPGN-32 T1
RPGN-3V T1A
RPGN-3V T2
RPGN-43 T1
RPGN-43 T1A
RPGN-43 T2A
RPGN-4V T2
SNGA-433 T2
SNGA-434 T2
SNGA-454 T2
SNGN-433 T1A
SNGN-433 T2
SNGN-433 T2A
SNGN-434 T1A
SNGN-434 T2
SNGN-453 T2
SNGN-454 T2
SPGN-322 T1A
SPGN-434 T2A
TPGN-322 T2A
WG A
WNGA-433 T2
RCGN-3V T1
RCGN-4V T1
RNGN-43 T2
RNGN-45 T1
RNGN-45 T1A
RNGN-45 T2
RNGN-45 T2A
RNGN-45A
ACHN-3222 T1A
ACHN-3422 T1A
CNGA-432 T2
CNGA-432 T2A
CNGA-433 T2
CNGA-434 T2
CNGA-434 T3A
CNGA-453 T2
CNGA-454 T2

40. Review
Silicon Nitrides have their place in the high speed ceramic machining market.
Grades such as Greenleaf GSN-100 work well in interrupted cutting and Milling operations due to Silicon Nitrides high thermal shock resistance.
Greenleaf GSN-100 works well in the machining of Gray, Ductile, and Nodular cast irons.
Although developed for Cast Iron machining, Greenleaf GSN-100 works on other materials such as selected high temp alloys.
You will want to start gearing your HSN customers to the new Greenleaf GSN-100.

41. Questions?

42. Thank
You!