Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and...

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Transcript of Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and...

Page 1: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf
Page 2: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Unique Tooling Solutions for Maximizing Productivity

Matt GossApplications EngineerGreenleaf Corporation

Page 3: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Founded in 1945 by Walter Greenleaf, Sr.

Family owned and operated

Facilities in PA and NC

450 + Employees

Sales in over 60 countries

Greenleaf Europe and Greenleaf China

Saegertown, PA Location

Greenleaf Corporation designs and manufactures standard and special Ceramic and Carbide Inserts and the supporting Steel Tooling.

ISO 9001 Since 1994

Page 4: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Aerospace Oil & Gas, Energy Die & Mold

Roll Turning & Heavy Machining

Where You Find Greenleaf

Bar Peeling & Tube Scarfing

Railroad

Crank/Cam

Page 5: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

1945

1971

1973

1985

WG600

WG700

XSYTIN®-1

A History of Continuous Innovation

1945

1971

1973

1985

2006 2016

2011

Page 6: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Today's Agenda

1. What are whisker-reinforced and phase-toughened ceramics?

2. Properties of whisker-reinforced and phase-toughened ceramics

3. Common HRSA materials suitable for machining with ceramics

4. Applications most suitable for machining with ceramics

5. Programming tips for machining with Ceramics

6. Tool maintenance and handling

7. Tool wear and how to evaluate tool life

Page 7: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

SiC Whiskers

Aluminum Oxide (Al2O3)

+

Whisker-Reinforced Ceramics

Page 8: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Whisker-Reinforced Ceramics

Page 9: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Phase-Toughened Ceramics

Page 10: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Unique ceramic blend

In-place grain growth

Phase-Toughened Ceramics

Page 11: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

54,000 PSI

174,000 PSI

100,000 PSI

Comparable Strength

Page 12: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

0

2

4

6

8

10

12

14

16

Speed

feed

Whisker-Ceramic Sialon Phase-Toughened

Phase-Toughened vs. Traditional Ceramics

Page 13: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Tool Life vs. Feed Rate

Page 14: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Cu

ttin

g Sp

ee

d

(SFM

)

Carbide

WHISKER-REINFORCED CERAMICSWG-300®/WG-600®/WG-700™

PHASE-TOUGHENED CERAMICSXSYTIN®-1

Feed(IPT)

Ceramic vs. Carbide Turning

How Ceramics Work

Page 15: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Whisker ceramics retain strength and hardness well beyond 1000°C

Carbide will turn to taffy at that temperature!

Heat Dissipation in Ceramic Machining

Page 16: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Super Alloys

Hardened Steel Machining

Cast Iron Machining

Oxide Ceramic(White) Al2O3

Black Ceramic

Al2O3 + TiC

Whisker-Reinforced

Ceramic

Silicon Nitride

GEM-19™ GEM-7™WG-300®WG-600®WG-700™

GSN100™

Phase-Toughened

Ceramic

XSYTIN®-1

Greenleaf Ceramic Grade Profile

Page 17: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Nickel AlloysInconel

WaspaloyHastelloy

Cobalt-Based AlloysStellites

Haynes AlloysWeld Overlays

Powdered Metals

HRSA Materials

Page 18: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Turbine Engine

Shafts

Cases

SpoolsBlisks

Discs

Oil & Gas

BOP

Flanges

Adapters

Valves

High-Temperature Resistance

Wear & Corrosion Resistance

HRSA Applications

Page 19: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Pre-ChamferingDOC Notching

Programming Techniques

Page 20: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Varying the Depth of Cut

Programming Techniques

Page 21: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

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Programming Techniques

Turning to a Shoulder

Page 22: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Ramping

Programming Techniques

Page 23: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Greenleaf Solution

Layout optimal tool path and step over for WG-6250-3

• 900 SFM (274 m/min)

• 0.0025 IPR (0,06 mm/rev)

• 1 insert per part

• 3-minute cycle time

Programming Techniques

Page 24: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Standard Edge Preps

Page 25: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Edge Prep for Interrupted Cutting

Page 26: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Cutter PositioningClimb (Down) MillingKeep cutter

engaged in cut

Programming Techniques

Page 27: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Tool Maintenance

Page 28: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Inspect the insert pocket, seating and clamping

Poor seating

Damaged shim seat

Bell-mouthed insertpocket

Tool Maintenance

Page 29: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Undesirable Tool Wear

Chipping Fracture

Ceramic Tool Wear

Page 30: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Typical Tool Wear

Ceramic Tool Wear

Flank Wear Notching

Page 31: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Heavy notch, light flank wear

Heavy notch, heavy flank wear

Proper Indexing Techniques

Page 32: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Greenleaf Special Tooling Solutions

Page 33: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Automotive

Page 34: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Special Milling Cutters

Page 35: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Aerospace Engines: Greenleaf’s Comfort Zone

Page 36: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Aerospace Engines: Greenleaf’s Comfort Zone

Page 37: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Blisk Machining1 Stage HP Turbine4 Stages HP Compressor

Spool PieceShaft

CenterFrame

OGV

LPCompressor

Disks

Compressor

CasingsHigh-Temperature

Casings

Aerospace Engines: Greenleaf’s Comfort Zone

Page 38: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Tool LayoutsTungsten Heavy-Metal Tooling

Page 39: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Tool LayoutsTungsten Heavy-Metal Tooling

Page 40: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Aerospace Engineering

High- and Mid-Pressure Coolant

Page 41: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

While Greenleaf has a full line of standard cutting tools, we have also custom designed and manufactured thousands of special

inserts and tools for aerospace and power generation parts.

Aerospace Engineering

Page 42: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Priority Components:Low Pressure Compressor Section

Page 43: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Rough Milling Blisk Slots

Page 44: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Slotting Cutter & Inserts – U.S. Patent Nos. 8,267,625 & 9,073,131

Rough Milling Turbine Disk Slots

Page 45: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Speed: 2874 SFM (876 m/min)Feed: 53 IPM (1346 mm)Chip Load: 0.0024 (0,06mm)

Part thickness: 1.13” (28,7mm)Time to feed: 1.3 seconds

Material: Rene 95, 48-50 HRc

Rough Milling Turbine Disk Slots

Page 46: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Example

One chamfer insert

One grooving insert

New machining parameters using WG-300®:Speed: 1,600 SFM (488 m/min)Feed: 0.0012 IPR (0,03 mm/rev) 28 second cut time!

Concept sold to many companies around the world.

Finishes groove in 1 plunge with 1 edge!

Overview of the Ring Max™ System

BX-169 Groove6.957” (171.71mm)

cutting diameter

Page 47: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

Technical Ceramics

Page 48: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf

• Cutting tools• Metal forming• Extrusion dies• Can tooling• Valves and seals• Pumps• Bearings• Fluid flow control

• Electronics• Microwave absorbers• Semiconductor components• Wear components• Medical components• Implants• Battery dies• Weld rolls

Technical Ceramics

Page 49: Unique Tooling Solutions for MaximizingFounded in 1945 by Walter Greenleaf, Sr. Family owned and operated Facilities in PA and NC 450 + Employees Sales in over 60 countries Greenleaf