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

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?

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)

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

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

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

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

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

Shock Resistance/ Strength Sub-Micron < 1µm G-20M, G-920, G-925, GA5026 G-01M , G9230 Fine Grain 1~2 µm G40, GA5025, G74 Wear Resistance/ Hardness 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-50, G5135 G-01 , GA-5040, G-910, G-915 Shock Resistance/ Strength

TURNING P- Steel M-Stainless Steel K-Cast Iron S- High Temp Alloy 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) S- High Temp Alloy (except Titanium) GA5023 (G02) S-Titanium G925(G20M) G-920 (G20M) G9230(G01M)

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

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

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

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

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

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

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

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

The Greenleaf ® Carbide Grade Profile

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

MT-CVD TiCN + TiN Coating 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

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

Most Economic “Go To” Grade 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

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

G-910 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 – M40 Application Range for ISO “K” Class Materials Cast Iron, Nickel Alloys, Non-Ferrous Metals K20 – K35

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

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

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

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

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

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

New… G-9230

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

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

Carbide Base Grade - G-20M Carbide Grade G-920 PVD TiN Coated Carbide Base Grade - G-20M ISO Application M-K-S 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

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

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

G-925 Carbide Grade Titanium, Nickel and Cobalt alloys 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

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

MT-CVD (TiCN + Al2O3 + TiN) Carbide Grade GA-5026 MT-CVD (TiCN + Al2O3 + TiN) Carbide Base Grade G-20M ISO Application M-K-S High Speed Grade High Wear Resistance Extended Tool Life

GA-5026 Carbide Grade MT-CVD (TiCN + Al2O3 + TiN) ISO Application M15-K05-S05 Higher Hot Hardness Resistance to Cratering due to Al2O3 Light Hone Recommended Good Steel Finishing Grade (FF2 or TF)

ISO Application Range M-K Carbide Grade G-02 MT CVD ( TiCN + Al2O3) ISO Application Range M-K Uncoated Grade for Cast Iron, Aluminum, Brass, Copper, etc.

GA-5023 MT CVD ( TiCN + Al2O3) Carbide Base Grade G-02 Carbide Grade GA-5023 MT CVD ( TiCN + Al2O3) Carbide Base Grade G-02 ISO Application Range M-K High Speed Grade Rough and Finish Applications Light Interrupted Cuts

GA-5023 Carbide Grade MT CVD ( TiCN + Al2O3) ISO Application Range M20 - K15 First Choice for Cast, Ductile and Nodular Irons Good Finishing Grade for Stainless (use FF2)

G-5135 MT CVD ( TiCN + Al2O3) Carbide Base Grade G-50 Carbide Grade G-5135 MT CVD ( TiCN + Al2O3) Carbide Base Grade G-50 ISO Application Range P35-M30-K20 Tough Base Grade for Strength Alumina Coating for Resistance to Heat, Wear & Deformation Effective against Cobalt Enriched Grades

Field Results Against Competition Carbide Grade G-5135 Field Results Against Competition Material Speed(SFM) Feed DOC Competition Result  4140                        200-550               .015      .100        Korloy/Stellram              15% better tool life 4340                        250-500               .012      .125        ZCC                               12% better tool life 316 Stainless Steel   200-300               .008      .120        Korloy/ZCC                   10% better tool life 410 Stainless Steel   200-250               .006      .100        Seco/ZCC                     12% better tool life 17-4 PH                   200-300               .010      .075        Sumitomo/Mitsubishi    5% better tool life

First Choice for Turning or Milling at Medium Speeds… Carbide Grade 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

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

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

G-935 PVD - TiAlN Carbide Base Grade G-53 Carbide Grade 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

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

GA-5035 MT CVD ( TiCN + Al2O3 + TiN) Carbide Base Grade G-60 Carbide Grade GA-5035 MT CVD ( TiCN + Al2O3 + 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

GA-5035 MT CVD ( TiCN + Al2O3 + TiN) Carbide Grade GA-5035 MT CVD ( TiCN + Al2O3 + TiN) ISO Application Range P25 – M25 Apply at Moderate/High Speeds Moderate Feed Rates

G-9120 PVD TiAlN Coated Carbide Base Grade G-60 Carbide Grade G-9120 PVD TiAlN Coated Carbide Base Grade G-60 ISO Application Range P20-P35 Rough Turn & Mill of Steel Forgings/Castings Moderate Speeds Moderate to High Feeds

New… G-9120

GA5125 Carbide Grade MT CVD ( TiCN + Al2O3) Carbide Base Grade G-60 ISO Application Range P15-P30 Milling and Turning of Manganese Steels High Speeds Moderate Feeds

GA5125

GA-5025 MT CVD ( TiCN + Al2O3+ TiN) Carbide Grade GA-5025 MT CVD ( TiCN + Al2O3+ TiN) ISO Application Range P Continuous Turning Light Interruptions High Speeds Low/Moderate Feeds

GA-5025 MT CVD ( TiCN + Al2O3 + TiN) Carbide Grade GA-5025 MT CVD ( TiCN + Al2O3 + TiN) ISO Application Range P15 Application Areas: Tube Scarfing Medium to Finish Turning Cast Steels

Thank You