A Guide to Selecting Ceramic Grades Dale R. Hill Applications Engineer GREENLEAF CORPORATION Saegertown, PA.

A Guide toSelecting Ceramic Grades

Dale R. HillApplications Engineer

GREENLEAF CORPORATIONSaegertown, PA

Work Materials

Nickel-Based Alloys• Inconel

• Waspaloy • Hastelloy

Cobalt-Based Alloys • Stellite

• Haynes Alloys

Weld Overlays400 and PH Series Stainless Steels (post

heat treat)Hardened Steels (45 – 65 R/c)

Nodular and Chrome IronsPowdered Metals

Selecting Ceramic Grades

Ceramic Tool Materials

Alumina Oxide (White Ceramic)Alumina Oxide + TiC (Black Ceramic)

Alumina Oxide + SiC (Whiskered)Silicon Nitride - Sialon


Tool Application

Alumina Oxide + SiC (Whiskered) – All Materials

Alumina Oxide (White Ceramic) – Gray Cast Iron

Alumina Oxide + TiC (Black Ceramic) – Hardened Steels and Irons


Focus Materials

Nickel-Based Alloys • Inconel

• Waspaloy • Hastelloy

Cobalt-Based Alloys • Stellite

• Haynes Alloys

400 and PH Series Stainless Steels (post heat treat)


First Choice…

Alumina Oxide + SiC Whiskers

Greenleaf

® Grades WG-300 - WG-600 - WG-700

High Cutting SpeedResists Catastrophic Failure

Predictable Performance


The fracture toughness ofWG ceramics is enhanced by the phenomenon of whisker“pull-out”. A close examination of the fracture surface at 3000x will reveal not only a clear indication of the whiskers randomly dispersed throughout the matrix, but also the obvious hexagonal holes where whiskers have actually been pulled out in the fracture process. A large amount on energy is required to pull the whiskers out. This greatly enhances the fracture toughness and thereby the high predictability of the inserts.

The fracture toughness ofWG ceramics is enhanced by the phenomenon of whisker“pull-out”. A close examination of the fracture surface at 3000x will reveal not only a clear indication of the whiskers randomly dispersed throughout the matrix, but also the obvious hexagonal holes where whiskers have actually been pulled out in the fracture process. A large amount on energy is required to pull the whiskers out. This greatly enhances the fracture toughness and thereby the high predictability of the inserts.


Focus Materials

Hardened Steels and Irons (45 – 65 R/c)Weld Overlays

Focus Materials

Hardened Steels and Irons (45 – 65 R/c)Weld Overlays


Machining Hardened Materials with Greenleaf

® Ceramic Inserts

WG Ceramics can be successfully applied to the machining of materials other than nickel alloys. Some application areas include hardened alloy steels, hard irons, die and mold steels, and hard weld overlays.

WG Ceramics can be successfully applied to the machining of materials other than nickel alloys. Some application areas include hardened alloy steels, hard irons, die and mold steels, and hard weld overlays.

Common materials include : 4150, 52100, D2, A2, H13 Steels

Chilled Cast Iron, White Iron, Ni-hard, 400 Series Stainless, Weld Overlay


In addition to WG-300, WG-600 & WG-700, Greenleaf’s GEM-7 composite ceramic has an important place in the machining of hard materials. WG Ceramics & GEM-7 can be cost effective alternatives to CBN in the heavy roll turning, and die & mold industries.

GEM-7:

Hot pressed Al2O3 + TiC, is used primarily for turning steels and irons above 32 Rc. It offers high wear resistance and moderate strength. GEM-7 can also be used on heat-resist alloys for light finishing work.

GEM-19:

Cold pressed and sintered Al203 offers high abrasion wear resistance. It is best applied in grooving operations on gray cast irons.


C-CDH42 T4B GEM-7 – 400 SFPM, .012 IPR @ .150” DOC

(120 m/min, 0,3 mm/rev @ 3,8 mm DOC)

Forged Steel @ 55 Hr/c


DESIGNATION APPLICATION AREA

A For light finishing and grooving, also added to some negative lands

B Used in addition to heavy machining chamfers and lands

T2A For scale cuts, light interruptions, weld overlays, turning and milling of hardened materials

T4B Heavy machining inserts under ¾” IC (19mm), Roll turning,4V, CDH22, CDH33

T5B Heavy machining inserts over ¾” IC (19mm), Roll turning, LNMN’s, SNGN 866’s

T7A Similar application to T2A, use in heavier feed areas

T10B Heavy machining inserts over ¾” IC (19mm), Roll turning in Severe Conditons, CDH43, CDH53

Edge Prep for Heavy Machining


GEM-19 is best used on work material less than 35 Rc, while GEM-7 works best on work materials above 35 Rc.

GEM-19 is best used on work material less than 35 Rc, while GEM-7 works best on work materials above 35 Rc.


(91 m/min, 0,15 mm/rev @ 3,2 mm DOC)




(91 m/min, 0,15 mm/rev @ 3,2 mm DOC)



Milling with Ceramic Tools

Focus – Hardened Materials

Milling with Ceramic Tools

Focus – Hardened Materials


Recommended Grade Choice…

Alumina Oxide + Sic (Whiskers)

Greenleaf Grade WG-300 & WG-600


Milling Hardened Materials

C-4 Series Ceramic Milling CuttersC-4 Series Ceramic Milling Cutters

Excelerator® Milling System

Greenleaf C4, CP4 and Excelerator milling cutters are designed for high RPM applications.

Greenleaf C4, CP4 and Excelerator milling cutters are designed for high RPM applications.


Available in Inch or Metric diameters from 3/8 inch (10mm) to 12” (305mm).

Available in Inch or Metric diameters from 3/8 inch (10mm) to 12” (305mm).


Greenleaf ‘s Excelerator Ball End Mill offers the ability to use ceramic or carbide inserts in the same cutter body.

Available in Inch or Metric Diameters…

.375” - .500” - .625” - .750” & 1.0”

10mm - 12mm - 16mm - 20mm & 25mm

Greenleaf ‘s Excelerator Ball End Mill offers the ability to use ceramic or carbide inserts in the same cutter body.

Available in Inch or Metric Diameters…

.375” - .500” - .625” - .750” & 1.0”

10mm - 12mm - 16mm - 20mm & 25mm

T2A .006 - .008” (0,15mm x 0,2mm) wide Negative Landplus a .0005 - .001” (0,01mm – 0,02mm) Hone

Greenleaf

® Standard Edge Preps

T1A .002 - .004” (0,05mm x 0,1mm) wide Negative Landplus a .0005 - .001” (0,01mm – 0,02mm) Hone


NOTE – Ceramic Ball End Mill Inserts are ‘A’ Hone only!

C404 Cutter w / RNGN45 T2A WG-300 -- 850 SFPM, .004 IPT @ .07” DOC

(260 m/min, 0,1 mm/tooth @ 1,78 mm DOC)

P20 Tool Steel @ 55 Hr/c


WOC

Programmed feed per tooth is affected by chip thinning in two directions.

Axial Chip Thinning - Depth of Cut (DOC)

Radial Chip Thinning - Width of Cut (WOC)

DOC


• As the depth of cut is reduced the lead angle is increased on a round insert.

• This will create a thinner chip, which should be compensated for by increasing the feed rate.

The lead angle of a round insert is variable based on the depth of cut.


100 % Chip Load

90o Lead

Chip thickness is factored by the width & depth of cut, and further reduced by the lead angle.


45o Lead

70 % Chip Load

The lead angle affects a square insert by spreading the chip out over a longer surface.

•Maximum insert life can be achieved with a step-over width of 40 – 60%.

•As the width of cut decreases, you should increase feed to maintain acceptable average chip thickness.

•Width and depth of cut combined with feed rate control chip thickness.

WOC


Internal and External Circular Interpolation

Decrease Feed Increase Feed


The Excelerator Milling flyer has application data & tips for Hard Milling .

Starting Speed, Feed and Depth of Cut are based on material hardness and insert size.


Classification of Greenleaf

® Ceramics

Super Alloys

Hardened Steel Machining

Cast Iron Machining

Oxide Ceramic(White) Al2O3

Black CeramicsAl2O3 + TiC

Whisker ReinforcedCeramic

Silicon Nitride

GEM-19 GEM-7WG-300WG-600WG-700

GSN100

Sialon Ceramics

SIALOX


Greenleaf

® ceramic inserts can be used in a variety of high productivity machining in a wide range of materials. The key to success is the proper application of the principles discussed in the WG-300 Application Guide.

1. Use a toolholder system designed for ceramic inserts.

2. Use the strongest insert shape possible.

3. Use the largest corner radius possible.

4. Use the correct edge preparation for the application.

5. Use the thickest inserts available for roughing.

6. Use toolholders and bars with the largest cross section.

7. Consider heavy metal or carbide bars whenever possible.

8. Keep toolholder overhang to a minimum.

10. Rethink the process

Guidelines to Remember

A Guide to Selecting Ceramic Grades Dale R. Hill Applications Engineer GREENLEAF CORPORATION Saegertown, PA.

Documents

ceramic grades slide

ceramic grades dale

composite ceramic

whiskers greenleaf grades

machining of materials

machining hardened materials

mold steels

wg ceramics gem