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Greenleaf ® Carbide Profile Selecting The Right Grade Dale Hill Applications Engineer Technical Services.

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Presentation on theme: "Greenleaf ® Carbide Profile Selecting The Right Grade Dale Hill Applications Engineer Technical Services."— Presentation transcript:

1 Greenleaf ® Carbide Profile Selecting The Right Grade Dale Hill Applications Engineer Technical Services

2 Factors Affecting Grade Choice Work Material? Operation – Milling, Turning, Etc…? Roughing or Finishing? Objective –Improve Tool Life?, Solve Breakage Problem, etc…? Looking for General Purpose Tool?

3 What Makes Grades Different? Amount (%)of Tungsten Carbide (Wear) Amount (%)of Cobalt Binder (Strength) Grain Size of the Powder (Wear  Strength) Alloying Elements - TiC (abrasion) / TaC (hot hardness)

4 Carbide Grain Size Shock Resistance/ Strength Medium 2-3µm Fine 1-2 µm Coarse 3 ⁺ µm Sub-Micron < 1µm Wear Resistance/ Hardness

5 Sub-Micron Grain Carbide Grades ( <1µm) Shock Resistance/ Strength G01M, G9230 G-20M,GA-5026, G-920, G-925 Wear Resistance/ Hardness

6 Shock Resistance/ Strength Fine Grain Carbide Grades (1-2 µm) G-74 G-40 GA-5025 Wear Resistance/ Hardness

7 Medium Grain Carbide Grades (2-3µm) G-60, GA-5125, GA-5035, G-955, G9120 G-53, GA-5036, G-935 G-23 G-10 G-02, GA-5023 Wear Resistance/ Hardness Shock Resistance/ Strength

8 Coarse Grain Carbide Grades ( 3 ⁺ µm) G-50, G5135 G-01, GA-5040, G-910, G-915 Wear Resistance/ Hardness Shock Resistance/ Strength

9 Sub-Micron < 1µm G-20M, G-920, G-925, GA5026 G-01M, G9230 Fine Grain 1~2 µm G40, GA5025, G74 Medium Grain 2~3 µm G-60, GA-5125, GA-5035, G-955, G9120 G-53, GA-5036, G-935, G10, G-02, GA05023 Coarse Grain 3+ µm G-01, GA-5040, G-910, G-915 G-50, G5135 Wear Resistance/ Hardness Shock Resistance/ Strength

10 TURNING More Wear Resistant Toughest P- Steel GA5025 GA5035(G60) G955(G60) G9120 (G60) GA5125 (G60) G935(G53) G5135 (G50) G915(G01) GA5040(G01) M-Stainless Steel GA5026(G20M) GA925(G20M) G920(G20M) GA5023(G02) G01M G9230 (G01M) G915(G01) K-Cast Iron GA5026(G20M)GA5023(G02) G5135 (G50) G915(G01) GA5040(G01) S- High Temp Alloy (except Titanium) GA5026(G20M) GA925(G20M) G920(G20M) GA5023 (G02) G01M G9230 (G01M) G915(G01) S-Titanium G925(G20M) G-920 (G20M) G925(G20M) G01M G9230(G01M) G915(G01)

11 Basic Tool Wear Mechanisms Flank Wear Most Predictable Wear Possible Solutions… Reduce Speed More Wear Resistant Grade

12 Basic Tool Wear Mechanisms Crater Wear Possible Solutions… Reduce Feed Reduce Speed Apply Coolant

13 Basic Tool Wear Mechanisms Built-up Edge Possible Solutions… Increase Speed Increase Feed Edge Prep/Hone Change Coolant

14 Basic Tool Wear Mechanisms Chipping Possible Solutions… Use Stronger Grade Increase Edge Prep/Hone Increase Tool Lead Angle Check Tool Overhang Check Fixture

15 Basic Tool Wear Mechanisms Notching Possible Solutions… Change Lead Angle Change Edge Prep/Hone Reduce Feed Use Ramp cutting

16 Basic Tool Wear Mechanisms Thermal Cracking/ Heat Checking Possible Solutions… Adjust Coolant Supply Reduce Speed Reduce Feed Use Higher Hot Hardness Grade

17 Basic Tool Wear Mechanisms Deformation Possible Solutions… Reduce Speed Reduce Feed Coolant Flow Select Harder Grade

18 Basic Tool Wear Mechanisms Fracture Possible Solutions… Use Stronger Grade/Geometry Reduce Feed Reduce Depth of Cut Check Tool Overhang Check Fixture

19 The Greenleaf ® Carbide Grade Profile

20 G-01 Uncoated Carbide ISO Application P-M-K Carbide Grade Toughest Substrate Good Choice for Turning or Milling at Low Speeds… Stainless Steel Low Carbon Steel High Temperature Alloys

21 GA-5040 MT-CVD TiCN + TiN Coating Carbide Base Grade - G-01 ISO Application P-M-K Tough Substrate Thick Layer of TiCN for Added Abrasion Resistance Top TiN Layer

22 GA-5040 Designed for Severe Use Applications Low to Moderate Speeds Moderate to High Feeds Milling and Interrupted Cuts General Purpose Grade

23 GA-5040 Most Economic “Go To” Grade Questionable Machine Condition Poor Part Fixturing First Time Machining Material Widest Range of Application Spans Entire ISO “P M K” Range

24 G-910 PVD TiN Coated Carbide Base Grade - G-01 ISO Application P-M-K First Choice for Milling Titanium Low to Medium Speeds Medium to High Feed Good for Higher Rake / Sharper Edge

25 Application Range for ISO “M” Class Materials Alloyed Cast Irons, Austenitic Stainless, Heat Resistant M30 – M40 Application Range for ISO “K” Class Materials Cast Iron, Nickel Alloys, Non-Ferrous Metals K20 – K35 G-910 Application Range for ISO “P” Class Materials Steels (Cast/Stainless), Long Chip Malleable Irons P35 – P55

26 G-915 PVD TiAlN Coated Carbide Base Grade - G-01 ISO Application P-M-K Turning or Milling Grade First Choice for Stainless Steels Low to Medium Speeds Medium to High Feed

27 G-915 Application Range for ISO “P” Class Materials Steels (Cast/Stainless), Long Chip Malleable Irons P35 – P55 Application Range for ISO “M” Class Materials Alloyed Cast Irons, Austenitic Stainless, Heat Resistant M30 – M45 Application Range for ISO “K” Class Materials Cast Iron, Nickel Alloys, Non-Ferrous Metals K20 – K35

28 G-01M Uncoated Micro-Grain Carbide ISO Application M-S Carbide Grade Tough Sub-Micron Carbide Higher Feed and Interrupted Cuts Cast and Forged Scale Conditions More Wear Resistant Than G-01

29 Same ISO Range as G-01 Available in TurboForm (TF) Chipbreaker G-01M Uncoated Micro-Grain Carbide Carbide Grade

30 G-9230 PVD TiAlN Coated Carbide Carbide Grade Tough Sub-Micron Carbide Higher Feed and Interrupted Cuts Cast and Forged Scale Conditions Compliments Grade G-925 Carbide Base Grade - G-01M ISO Application M-K-S

31 G-9230 PVD TiAlN Coated Carbide Carbide Grade ISO Application M30-K20-S20 First Choice for Medium to Heavy Machining of… Nickel AlloysCobalt Alloys Titanium Alloys Stainless Steel Alloyed Irons

32 New… G-9230

33 G-20M Uncoated Micro-Grain Carbide ISO Application M20-K05-S05 Carbide Grade Sub-Micron Notch Resistant Grade Used on High Temperature Alloys Stands Up to Forging Scale/As Cast Materials

34 G-20M Good Choice for Low Speed, Light to Medium Machining of… Nickel AlloysCobalt Alloys Titanium AlloysAluminum Non-Ferrous Material Carbide Grade

35 G-920 PVD TiN Coated Finish Turning Thin Walled Parts Excellent Grooving Grade for Nickel Based Alloys Thermal Stability/ Low Coefficient of Friction Reduces Built Up Edge Machine Aluminum Alloys Instead of “J” Polish Carbide Base Grade - G-20M ISO Application M-K-S Carbide Grade

36 G-920 PVD TiN Coated ISO Application M15-K10-S05 Alloyed Cast Irons, Stainless Steels, Heat Resistant Available With ‘Up Sharp’ Edge Carbide Grade

37 G-925 PVD TiAlN Coated Carbide Base Grade G-20M ISO ApplicationM-K-S TiAlN Coating Properties are Suited for High Temperature Cutting Conditions Higher Speeds Than G-920 Carbide Grade

38 G-925 PVD TiAlN Coated ISO Application M15-K05-S05 First Choice for Light to Medium Machining of… Titanium, Nickel and Cobalt alloys Stainless Steels, Co-Cr-Mo and Cast Irons Carbide Grade

39 G-925 PVD TiAlN Coated Excellent Wear Grade For High Temp Alloys 2-3 Times Tool life over TiN Coated Insert Carbide Grade

40 GA-5026 MT-CVD (TiCN + Al 2 O 3 + TiN) Carbide Base Grade G-20M High Speed Grade High Wear Resistance Extended Tool Life Carbide Grade ISO ApplicationM-K-S

41 GA-5026 MT-CVD (TiCN + Al 2 O 3 + TiN) ISO Application M15-K05-S05 Higher Hot Hardness Resistance to Cratering due to Al 2 O 3 Light Hone Recommended Good Steel Finishing Grade (FF2 or TF) Carbide Grade

42 G-02 MT CVD ( TiCN + Al 2 O 3 ) Carbide Grade Uncoated Grade for Cast Iron, Aluminum, Brass, Copper, etc. ISO Application Range M-K

43 GA-5023 MT CVD ( TiCN + Al 2 O 3 ) Carbide Base Grade G-02 High Speed Grade Rough and Finish Applications Light Interrupted Cuts ISO Application Range M-K Carbide Grade

44 GA-5023 MT CVD ( TiCN + Al 2 O 3 ) ISO Application Range M20 - K15 First Choice for Cast, Ductile and Nodular Irons Good Finishing Grade for Stainless (use FF2) Carbide Grade

45 G-5135 MT CVD ( TiCN + Al 2 O 3 ) Carbide Base Grade G-50 Tough Base Grade for Strength ISO Application RangeP35-M30-K20 Carbide Grade Effective against Cobalt Enriched Grades Alumina Coating for Resistance to Heat, Wear & Deformation

46 G-5135 MaterialSpeed(SFM) Feed DOCCompetitionResult Korloy/Stellram 15% better tool life ZCC 12% better tool life 316 Stainless Steel Korloy/ZCC 10% better tool life 410 Stainless Steel Seco/ZCC 12% better tool life 17-4 PH Sumitomo/Mitsubishi 5% better tool life Carbide Grade Field Results Against Competition

47 G-5135 Antique to new CNC machines, out-of round parts, Heavy Scale & Slag at a variety of speeds/feeds/doc’s First Choice for Turning or Milling at Medium Speeds… Forged Alloy Steel Ductile Iron Carbide Grade

48 G-5135 Current Stocking Program… CNMG643 MR – CNMG644 MR SNMG644 MR – SNMG866 MR TNMG666 MR Carbide Grade

49 G-53 Uncoated Carbide ISO Application P-M Carbide Grade Uncoated General Purpose Steel Milling Grade Forged/Cast Steels 400 Series Stainless Steels Moderate Speed at Medium to High Feed

50 G-935 PVD - TiAlN Carbide Base Grade G-53 ISO Application Range P15-P45 General Purpose Steel Milling Grade Improved Tool Life and Speed over G-53 Deep Depth of Cut Medium Speed at Medium to High Feed Carbide Grade

51 G-60 Uncoated Carbide ISO Application P-M Carbide Grade Uncoated General Purpose Steel Turning Grade Forged/Cast Steels 400 Series Stainless Steels

52 GA-5035 MT CVD ( TiCN + Al 2 O 3 + TiN) Carbide Base Grade G-60 ISO Application Range P-M All Purpose Turning Grade for Most Steels Good Resistance to Deformation 400 and PH Stainless Steels Carbide Grade

53 GA-5035 MT CVD ( TiCN + Al 2 O 3 + TiN) ISO Application Range P25 – M25 Apply at Moderate/High Speeds Moderate Feed Rates Carbide Grade

54 G-9120 PVD TiAlN Coated Carbide Base Grade G-60 ISO Application RangeP20-P35 Rough Turn & Mill of Steel Forgings/Castings Moderate Speeds Moderate to High Feeds Carbide Grade

55 New… G-9120

56 GA5125 MT CVD ( TiCN + Al 2 O 3 ) Carbide Base Grade G-60 ISO Application RangeP15-P30 Milling and Turning of Manganese Steels High Speeds Moderate Feeds Carbide Grade

57 GA5125

58 GA-5025 MT CVD ( TiCN + Al 2 O 3 + TiN) Carbide Grade ISO Application Range P Continuous Turning Light Interruptions High Speeds Low/Moderate Feeds

59 GA-5025 MT CVD ( TiCN + Al 2 O 3 + TiN) ISO Application Range P15 Application Areas: Tube Scarfing Medium to Finish Turning Cast Steels Carbide Grade

60 Thank You


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