2Greenleaf ® GSN-100 GSN to GSN-100 Review of Silicon Nitrides GSN-100 DescriptionCurrent data and successesTurningGray IronDuctile IronMillingOther applicationsGSN-100 vs. HSN-100 & 200
3Silicon Nitrides Greenleaf ® GSN-100 Developed for Cast Iron ApplicationsHigher thermal shock resistance when compared to Whisker CeramicsLower high temperature stability compared to Whisker CeramicsBest in interrupted cutting due to high thermal shock resistanceScaleMilling
4Greenleaf ® GSN-100An 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.
8Gray 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 insertCycle time minutes5X greater tool lifeSFM is 2X present toolFeed rate is 4X present tool.Inserts ran parts for 3+ days before needing changed.
21Gray Cast Iron, as cast We are running: Milling Cutter- C404 Insert- CNGN-454 (CNGN120716)Two Nests are used so both the 80⁰ and100⁰ corners of the Insert can be utilizedMaterial – Gray Cast IronGrade- GSN-100 (GSN-100)DOC ( mm)Speed- 4,000- 5,000 SFM (1,220- 1,525 M/Min)Feed ( mm) Fd/InsertCut time- approx. 80 minutes per Insert index.A 3⁰ reverse lead cartridge is usedto circle interpolate Bores
31Jethete M152A 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.
32Jethete M152 32-36 R/C 2 minutes cut time, inserts burned, Cutter: WSRP RHInsert: RPGN-43 T1A HSN-200Speed: 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
3742 R/C age hardened Waspaloy Cutters InsertsFMRN-050RFMRN-063R RNGN-45FMRN-080R T2AFMRN-100RFMRP-5040R RPGN-43FMRP-6340R T2AFrom 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)
40ReviewSilicon 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.