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Cermets

Cermets. CER AMIC + MET AL. CERMET. What’s CERMET. Both advantages of Ceramic & Metal. What’s CERMET advantages ?. CERMET Triple Advantages. High Speed Availability (+ ~ 25%) (150 – 600 m/min). (2) Longer Tool Life = High Economy.

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Cermets

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  1. Cermets

  2. CERAMIC + METAL CERMET What’s CERMET Both advantages of Ceramic & Metal

  3. What’s CERMETadvantages ? CERMET Triple Advantages • High Speed Availability (+ ~ 25%)(150 – 600 m/min) (2) Longer Tool Life = High Economy (3) Excellent Finishing Surface

  4. CERAMIC CERMET Wear Resistance CARBIDE Toughness What’s CERMETarea ?

  5. Super Micro-Grain Cermet TN6020

  6. Super Micro-Grain Cermet Smaller size 2um Normal TN6020

  7. PVD coated Super micro-grain cermet PV7020

  8. PV7020 TiN coating Chip removal, distinction for used edge FS coating (TiAlN) Suitable for high speed machining, Good wear resistance Super micro grain cermet (TN6020) Good wear resistance Good crack resistance High strength Super micro-grain composition 2μm PVD coating with surface smoothness Wear Resistance and High Temp. Stability

  9. Mixed Ceramics

  10. Soft and Hard Turning 40-60 HRc Mixed Ceramic A65 Roughing (vc = 250 - 500 m/min)

  11. Hard Turning 58-67 HRc Coated Ceramic A66N Roughing and finishing (vc = 150 - 400 m/min)

  12. 1. A66N’s Minute and Unified grain contribute to its excellent Wear resistance and toughness. A66N Conventional 2. Improved physical properties Bending strength Hardness Anti-oxidation A66N 1,000 20 2.1 Conventional 800 19 2.8 Coated Ceramic A66N = Features =

  13. Coated Ceramic A66N = Advantages = 1. Against conventional CERAMIC = Stable machining with its excellent quality 2. Against CBN tools = Can cover some CBN machining area, which means great cost down.

  14. What is the suitable application or workpiece, which A66N can show its advantage ? Coated Ceramic A66N = Applications(Against CBN) = 1. Hardness ; Available up to HRC 60 - 65 2. Material ; Hardened steel, Die steel, Sintered material.. 3. Parts ; Gear blanks, Crank shaft, Valve sheet, Compressor turbin…… ( Mostly for Automobile parts. ) Let’s try A66N against CBN at Automobile industry !! and OPEN NEW MARKET !!!

  15. Coated Ceramic A66N = Test Data 1 (Toughness comparison) = Company A Nose wear (mm) SKD11(HRC60) V=100 m/min d=0.5mm, f=0.2mm/rev CNGA120408, WET Time (min.)

  16. Hard Turning 58-67 HRc Megacoated Ceramic PT600M Roughing and finishing (vc = 150 - 400 m/min)

  17. Microstructure PT600M（KT66） Conventional Fine structure prevents sudden failure High oxidation resistance prevents flaking Good chemical stability brings good wear resistance High fracture toughness brings stability in low speed interrupted cutting

  18. Special Coating Oxidation resistance(≧1000℃） ⇒ Reduce oxidation wear and diffusive wear Special Coating Hardness (Hv) TiCN TiAlN TiN 300 500 700 900 1100 1300 Oxidation temperature (℃)

  19. 0.15 A65 KT66 0.12 A65+ MEGACOAT 0.09 cBN B Nose wear (mm) cBN A PT600M (KT66+MEGACOAT) 0.06 0.03 0.00 0 5 10 15 20 25 30 35 Cuttig Time (min) Cutting conditions：vc=100m/min, ap=0.2mm, f=0.1mm/rev, wet Work piece：SCM415H (Case Hardening) (HRC=58～62)

  20. 0.15 A65 KT66 0.12 0.09 cBN B Nose wear (mm) cBNA 0.06 A65 ＋MEGACOAT 0.03 PT600M (KT66+MEGACOAT) 0.00 0 5 10 15 20 25 30 35 Cuttig Time (min) Cutting conditions：vc=100m/min, ap=0.2mm, f=0.1mm/rev, Dry Work piece：SCM415H (Case Hardening) HRC=58～62

  21. PT600M (KT66+MEGACOAT) KT66 A65 +MEGACOAT A65 Number of hits Cutting Condition ：vc=150m/min, ap=0.2mm, f=0.15mm/rev, dry Workpiece：SCM415H (Case Hardening) HRC=58～62

  22. Silicon Nitride !

  23. Cast iron Machining Roughing Power of excellents With Silicon Nitride !

  24. KS6000 / KS500 / KX207 *Silicon Nitride Ceramic for roughing and semi finish *Both,Wet and Dryis possible * Cutting Speed Range (700 - 1600 m/min) *Stable and Long tool life

  25. CBN

  26. New CBN generation is comming! KBN510 & KBN525 (Micro Grain structure)

  27. KBN10NBB-KBN25NBB new CBN New • KYOCERA CBN – BB chip breaker • KYOCERA CBN : KBN 10 N and KBN 25 N >> BB – Geometrie • Inovative combination of CBN-application and Carbide-geometrie. • Good chip control by surface hardened steel (40HRC). • Chip breaker geometrie for chip transportation and chip forming. • 3 CBN-sizesfor certain application. • 2 coated CBN – grades • Without coolingl • KBN 10N > finishing – continuous and light interrupted cut • 100 bis 180 m/min • KBN 25N > Semi-finishing – continuous to heavy interrupted cut • 80 bis 170 m/min • Application example CrMo – Steel , 15CrMo5 • Steel with 60 HRC • ap (mm) f (mm/U) Important! • BB1 0,1 - 0,5 0,05 - 0,15 Description example CNGM 120404/08/12 BB1 • BB2 0,2 - 0,6 0,1 - 0,17 TNGM 160404..... • BB3 0,3 - 0,7 0,12 - 0,2 DNGM 150404...BB3 KBN 10 • Steel with 40 HRC • BB1 0,1 - 0,5 0,1 - 0,2 • BB2 0,3 - 0,8 0,15 - 0,25 • BB3 0,5 - 1,1 0,2 - 0,3

  28. “Cell Fiber Structure Ceramics Composite Materials” Our Target for Inconel 718!

  29. Cell Fiber Technology Shell (White area) Core (Gray area) Core / Shell Cell Fiber Structure Diamond / WC-Cofor Drilling Application Si3N4/ BN (Sinboron )for Turbine Engine ZrB2/ BN (Zirboron )for Rocket & Solar Thermal Propulsion HfB2/ BN (Hafboron )for Rocket & Solar Thermal Propulsion HfC/ WRefor X-Ray Target & Rocket Propulsion WC-Co / Nifor Concrete & Steel Cutting WC-Co / W-Ni-Fefor Drilling Application etc.

  30. In-house test of CF1 Random packed Multi fiber Length : 3mm Diameter : 1mm Cell (Minimum unit) 50um

  31. Cell fiber technology • Core • High Hardness ….. Wear resistance • Shell • High Toughness ….. Chipping Resistance Crack propagation resistance 200μm Surface Cutting performance can be controlled by changing the combination. Indentation Test (Vickers Hardness)

  32. Conclusions Performance of CF1 (KX213) in Ni based alloy machining is good at higher cutting speed (500m/min) for finishing application such as less than ap 1.5mm. Lower cutting speed is also available such as 200-300m/min. However, to show the difference against WG300 (Wisker),we recommend higher cutting speed. We recommend workpiece material hardness need to be under HRC 45. To choose suitable edge preparation is very important

  33. Thank you for your attention

  34. www.simeonetools.com global.kyocera.com VIA DELLA GERBOLA 10/A 10071 CERETTA di s. Maurizio C.se (TO) 011 9279348 fax 011 9244206 mail@simeonetools.com simeone@simeonetools.com blardone@simeonetools.com vantaggiato@simeonetools.com ferina@simeonetools.com ambrosini@simeonetools.com

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