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

Greenleaf

® Carbide ProfileSelecting The Right Grade

Dale HillApplications 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)

Carbide Grain Size

Shock Resistance/ Strength

Medium 2-3µm

Fine 1-2 µm

Coarse 3 µm⁺

Sub-Micron < 1µm

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Sub-Micron Grain Carbide Grades ( <1µm)


G01M, G9230

G-20M ,GA-5026, G-920, G-925

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Fine Grain Carbide Grades (1-2 µm)

G-74

G-40

GA-5025

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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

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Coarse Grain Carbide Grades ( 3 µm) ⁺

G-50, G5135

G-01, GA-5040, G-910, G-915

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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

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TURNING More Wear Resistant Toughest

P- Steel GA5025GA5035(G60)

G955(G60)G9120 (G60)

GA5125 (G60)G935(G53)

G5135 (G50)G915(G01)

GA5040(G01)

M-Stainless SteelGA5026(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)

Basic Tool Wear Mechanisms

Flank WearMost Predictable Wear

Possible Solutions…Reduce SpeedMore Wear Resistant Grade


Crater Wear

Possible Solutions…Reduce FeedReduce SpeedApply Coolant


Built-up Edge

Possible Solutions…Increase SpeedIncrease FeedEdge Prep/Hone ChangeCoolant


Chipping

Possible Solutions…Use Stronger GradeIncrease Edge Prep/HoneIncrease Tool Lead AngleCheck Tool OverhangCheck Fixture


Notching

Possible Solutions…Change Lead AngleChange Edge Prep/HoneReduce FeedUse Ramp cutting


Thermal Cracking/ Heat Checking

Possible Solutions…Adjust Coolant SupplyReduce SpeedReduce FeedUse Higher Hot Hardness Grade


Deformation

Possible Solutions…Reduce SpeedReduce FeedCoolant FlowSelect Harder Grade


Fracture

Possible Solutions…Use Stronger Grade/GeometryReduce FeedReduce Depth of CutCheck Tool OverhangCheck Fixture

The Greenleaf

® Carbide

Grade Profile

G-01Uncoated Carbide

ISO Application P-M-K

Carbide Grade

Toughest SubstrateGood Choice for Turning or Milling at Low Speeds…

Stainless SteelLow Carbon Steel

High Temperature Alloys

GA-5040MT-CVD TiCN + TiN Coating

Carbide Base Grade - G-01


Tough SubstrateThick Layer of TiCN for Added Abrasion ResistanceTop TiN Layer

GA-5040

Designed for Severe Use ApplicationsLow to Moderate Speeds Moderate to High Feeds

Milling and Interrupted CutsGeneral Purpose Grade

GA-5040Most 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-910PVD TiN Coated



First Choice for Milling Titanium Low to Medium Speeds Medium to High FeedGood for Higher Rake / Sharper Edge

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-910Application Range for ISO “P” Class Materials

Steels (Cast/Stainless), Long Chip Malleable Irons

P35 – P55

G-915PVD TiAlN Coated



Turning or Milling Grade

First Choice for Stainless Steels

Low to Medium Speeds

Medium to High Feed

G-915Application 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-01MUncoated Micro-Grain Carbide

ISO Application M-S

Carbide Grade

Tough Sub-Micron CarbideHigher 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-9230PVD TiAlN Coated Carbide

Carbide Grade

Tough Sub-Micron CarbideHigher Feed and Interrupted Cuts

Cast and Forged Scale ConditionsCompliments Grade G-925

Carbide Base Grade - G-01M

ISO Application M-K-S

G-9230PVD TiAlN Coated Carbide

Carbide Grade

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-9230Greenleaf

Greenleaf Drive FIELD DEMONSTRATION Saegertown, PA 16433 REPORT

(814) 763-2915 Company: XYZ Company Greenleaf Rep: Sean Delaney

Address: Test Contact: TELE:

Tele:

City: Quote Contact: TELE:

Tele:

State, Zip:

Machine: Mazak Integrex 200 IIY

Part Name: Front Sump

Operation:

Power: 35 HP Dwg: Greenleaf Holder: Comp:

Present Holder:

RPM: 5,000 Material: 17-4 PH SS Insert: CNMG 432 GP2

Condition: Good Hardness: 32 Rc Grade: G9230

Chucking: Standard 3 Jaw Condition: Good Edge:

Coolant: Yes

Type of Cut: ID and OD Turn

Other: Heavy Interruption

DEMONSTRATION OBJECTIVE: To outperform Kennametal KC 5525

Edge: RPM: DIA: SFM: IPT/ IPR:

LOC/ TIME:

DOC: WOC: Parts: Remarks/Changes:

Present:

1. 300 4”-7” 350 .008 .50-.150 1 Insert still looked good after 1 part

2.

3.

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5.

6.

SUMMARY:

This insert was our second attempt. I started with G915 and we ran the same parameters as above. The insert had noticeable nose wear after 1 part so we made the change to G9230. G9230 definitely outperformed G915 in this application. We will do an extended test with this insert. #F241A April 22, 2004 {F2421A.doc/I:\FORMS}

`

Date: Test #: 001



Carbide Grade

Sub-Micron Notch Resistant GradeUsed on High Temperature Alloys

Stands Up to Forging Scale/As Cast Materials

G-20M

Good Choice for Low Speed, Light to Medium Machining of…

Nickel Alloys Cobalt Alloys

Titanium Alloys Aluminum

Non-Ferrous Material

Carbide Grade

G-920PVD TiN Coated

Finish Turning Thin Walled PartsExcellent Grooving Grade for Nickel Based AlloysThermal Stability/ Low Coefficient of Friction Reduces Built Up Edge Machine Aluminum Alloys Instead of “J” Polish

Carbide Base Grade - G-20M


Carbide Grade

G-920PVD TiN Coated


Alloyed Cast Irons, Stainless Steels, Heat Resistant

Available With ‘Up Sharp’ Edge

Carbide Grade


Carbide Base Grade G-20M


TiAlN Coating Properties are Suited for High Temperature Cutting Conditions

Higher Speeds Than G-920

Carbide Grade



First Choice for Light to Medium Machining of…

Titanium, Nickel and Cobalt alloys Stainless Steels, Co-Cr-Mo and Cast Irons

Carbide Grade


Excellent Wear Grade For High Temp Alloys2-3 Times Tool life over TiN Coated Insert

Carbide Grade

GA-5026MT-CVD (TiCN + Al2O3 + TiN)

Carbide Base Grade G-20M

High Speed GradeHigh Wear ResistanceExtended Tool Life

Carbide Grade


GA-5026MT-CVD (TiCN + Al2O3 + TiN)


Higher Hot HardnessResistance to Cratering due to Al2O3

Light Hone RecommendedGood Steel Finishing Grade (FF2 or TF)

Carbide Grade

G-02MT CVD ( TiCN + Al2O3)

Carbide Grade

Uncoated Grade for Cast Iron, Aluminum, Brass, Copper, etc.

ISO Application Range M-K

GA-5023MT CVD ( TiCN + Al2O3)Carbide Base Grade G-02

High Speed GradeRough and Finish ApplicationsLight Interrupted Cuts

ISO Application Range M-K

Carbide Grade

GA-5023MT CVD ( TiCN + Al2O3)

ISO Application Range M20 - K15

First Choice for Cast,Ductile and Nodular Irons

Good Finishing Grade for Stainless (use FF2)

Carbide Grade

G-5135MT CVD ( TiCN + Al2O3)Carbide Base Grade G-50

Tough Base Grade for Strength

ISO Application Range P35-M30-K20

Carbide Grade

Effective against Cobalt Enriched Grades

Alumina Coating for Resistance toHeat, Wear & Deformation

G-5135

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

Carbide Grade

Field Results Against Competition

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 SteelDuctile Iron

Carbide Grade

G-5135

Current Stocking Program…

CNMG643 MR – CNMG644 MR

SNMG644 MR – SNMG866 MR

TNMG666 MR

Carbide Grade


ISO Application P-M

Carbide Grade

Uncoated General Purpose Steel Milling GradeForged/Cast Steels

400 Series Stainless SteelsModerate Speed at Medium to High Feed

G-935PVD - 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


ISO Application P-M

Carbide Grade

Uncoated General Purpose Steel Turning GradeForged/Cast Steels

400 Series Stainless Steels

GA-5035MT CVD ( TiCN + Al2O3 + TiN)


ISO Application Range P-M

All Purpose Turning Grade for Most Steels

Good Resistance to Deformation

400 and PH Stainless Steels

Carbide Grade


ISO Application Range P25 – M25

Apply at Moderate/High Speeds

Moderate Feed Rates

Carbide Grade




Rough Turn & Mill of Steel Forgings/CastingsModerate Speeds

Moderate to High Feeds

Carbide Grade

New… G-9120Greenleaf

FIELD TEST REPORT

Company: ABC Company Greenleaf Rep: Travis Biggs


Tele:


Tele:

State, Zip:

Machine: Ingersoll Part Name: Operation: Mill

Power: 300hp Dwg: Greenleaf Holder: Comp:

24”mill Present Holder:

RPM: Material: P-20C Modified

Insert: 428522

Condition: Hardness: 277-311 bhn Grade: G9120

Chucking: Condition: Scale & clean Edge:

Coolant: NO Type of Cut: Mill - climb Other:

DEMONSTRATION OBJECTIVE: Testing G9120

Edge: RPM: DIA.: SFM: IPT: LOC/ TIME:

DOC: WOC: parts: Remarks/Changes:

Present: 66 24” 414 .0085 45min .437 18” 1/2 Chipping on cutting edge

1. Clean

66 24 414 .0085 45 .437 18” Little wear/didn’t need to index

Scale 66 24” 414 .0085 45 .437 18” 1 Next part with scale and same edge from previous part

3.

4.

5.

SUMMARY:

According to the operator he needs to index the inserts after the first cut with previous tool. With G9120 we were able to make the entire cut and the edge was still good enough to rough the next part that had scale.

Date: 1-24-12 Test #:

GA5125MT CVD ( TiCN + Al2O3)



Milling and Turning of Manganese SteelsHigh Speeds

Moderate Feeds

Carbide Grade

GA5125Greenleaf

Greenleaf Drive FIELD DEMONSTRATION Saegertown, PA 16433 REPORT

(814) 763-2915 Company: XXX Rail Company Greenleaf Rep: Greg Devine / RRM


Bob Tele:


Tele:

State, Zip: IL

Machine: MTR Mill # 2 Part Name: Switch Point Operation:

Power: 50 HP Dwg: Greenleaf Holder: Comp:

14 deg mill Present Holder:

RPM: Material: Rail Steel Insert: SPE 55 L02 / R02 (430436 /430437)

Same

Condition: Good Hardness: 400 BHN Grade: GA5125 VR77

Chucking: Magnetic Condition: Scale Edge: .004 - .006 Hone

Coolant: No Type of Cut: Side Mill Other:

DEMONSTRATION OBJECTIVE: Outperform VR Wesson & Ingersoll grades milling rail steel.

Edge: RPM: DIA.: SFM: IPM: LOC/ TIME:

DOC: WOC: IPT Remarks/Changes:

Present: VR77

(161) 153

9 (380)360

(16) 13

39 feet Var .75” .013

1. GA5125

212 9 500 16 39 feet Var .75” .0125

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5.

6.

SUMMARY:

Shop manager said this was the toughest & hardest rail steel that they run. In his experience no company had been able to run 500 SFM. (Many had tried)

The operators normally turn the feed and speed overrides down to the values listed above. We ran at 100% of our programmed feed & speed which is significantly faster than the present parameters. The VR Wesson or Ingersoll inserts must be indexed 3 times during this operation. We were able to complete the entire gage cut on this switch point without indexing an insert. Only 1 insert had a small chip due to a bad screw which Greg had marked before running our inserts. The manager was very impressed, and requested an immediate quote. Greg will continue with further testing with the expectation that we can ran at 600 SFM with this grade.

Date: Test #:

GA-5025MT CVD ( TiCN + Al2O3+ TiN)

Carbide Grade

ISO Application Range P

Continuous TurningLight InterruptionsHigh SpeedsLow/Moderate Feeds


ISO Application Range P15

Application Areas:

Tube Scarfing

Medium to Finish Turning Cast Steels

Carbide Grade

Thank You

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

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