Greenleaf ® GSN-100 Greenleaf ® GSN-100. Greenleaf ® GSN-100 GSN to GSN-100 Review of Silicon Nitrides GSN-100 Description Current data and successes.

Greenleaf

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GSN-100Greenleaf

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GSN-100

Greenleaf

® GSN-100Greenleaf

® GSN-100GSN to GSN-100

Review of Silicon Nitrides

GSN-100DescriptionCurrent data and successes

TurningGray IronDuctile Iron

MillingGray IronDuctile Iron

Other applicationsGSN-100 vs. HSN-100 & 200

Silicon NitridesSilicon Nitrides

Greenleaf

® GSN-100Developed for Cast Iron Applications

• Higher thermal shock resistance when compared to Whisker Ceramics

• Lower high temperature stability compared to Whisker Ceramics

• Best in interrupted cutting due to high thermal shock resistance• Scale• Milling

Greenleaf

® GSN-100Greenleaf

® GSN-100

An engineered blend of silicon nitride and proprietary toughening agents that redefine productivity in

the machining of cast iron.

GSN100 delivers outstanding tool life at high cutting speeds in turning,

grooving and milling applications.

GSN-100 Test DataGSN-100 Test Data

GSN-100 Class 30 Gray Iron TurningGSN-100 Class 30 Gray Iron Turning

Gray Cast Iron, class 30, 20 R/CGray Cast Iron, class 30, 20 R/C

• Competitor: GC-4187 K40C• 2000 SFM (610 M/Min)• .004 IPR plunge (0,10 mm/rev)• .008 IPR turn (0,20 mm/rev)

• Greenleaf

® WG-6218-2A SG-0173• 4000 SFM (1220 M/Min)• .008 IPR plunge (0,20 mm/rev)• .012 IPR turn (0,30 mm/rev)

•This customer presently running competitor GC-4187 K40C grade and completing 15 parts per insert with a cycle time of 13.44 minutes.

•Ran test with WG-6218-2A GSN-100 insert and completed 74 parts per insert

•Cycle time 11.38 minutes

•5X greater tool life

•SFM is 2X present tool

•Feed rate is 4X present tool.

•Inserts ran parts for 3+ days before needing changed.

Gray Cast Iron, class 30, 20 R/CGray Cast Iron, class 30, 20 R/C

GSN-100 Class 435 Gray Iron Turning

GSN-100 Class 435 Gray Iron Turning

The areas of focus for testing were:Tool #1 Back Face and Rough Pilot

Area of focus

Round 1 testingRound 1 testing

Customer target: 150 parts per edge

Tool #1 - Back Face and Rough Pilot

Round 1 testingRound 1 testing

Customer target: 150 parts per edge

Date: 16-Jan-12 Operator:Customer: Engineer:Machine: HONOR VL-86 Cell 2BCoolant: no

Present GreenleafOperation: back faceInsert Manufacturer sumitomoInsert: CNGX-434 CNGA-458Edge Prep: T2Grade: BNS800 GSN100Toolholder:

Insert Price ($): $88.00 $9.74 # edges/insert 4 4Price/ edge ($) $22.00 $2.44Passes/ edge 150 168Insert cost/ Pass $0.15 $0.01

Burden rate ($/hour) $60.00 $60.00Passes to finishing cut: 1.00 1.00

# of indexes/ pass 0 0Time to index (sec) 60 60Cost to index ($) $0.00 $0.00

Part Diameter (in.): 11.085 11.085speed (sfm) 3000 3000RPM (rev/min) 1034 1034DOC (in.) 0.2 0.2Feed (in/rev) 0.02 0.02LOC (in.) 4.611 4.611

removal rate (in3/min): 19.07 19.07Cut time for 1 pass(min): 0.22 0.22Cost to cut ($): $0.22 $0.22

Cost to cut 1 Pass: $0.37 $0.24Cost to complete all passes: $0.37 $0.24

Total cycle time (min): 0.22 0.22

Parts/Year 93,600Cost/Year $34,602.88 $22,231.53

Cost savings/year $12,371.36

Cost/day $2,587.82 $1,662.61Cost/week $12,939.11 $8,313.07Cost/year $672,833.83 $432,279.66

Total cost savings/year $240,554.17

Total manufacturing at 7000 Parts/day at 5 days per week

INSERT COST PER PART

BURDEN RATE COST OF PART

INSERT JUSTIFICATION FOR TURNING

based on 15 parts/hr, 3 shifts, 5 days a week, cell 2B

SFM VARIES DUE TO DIAMETER RANGEDIA. RANGE 8.779-13.39

The areas of focus for testing were:Tool #3 – Inboard Bottom Face.

Tool #6 – Finish Pilot

Tool #6

Tool #3

Round 2 testingRound 2 testing

Customer target: 300 parts per edge

Tool #3 – Inboard Bottom Face.

Round 2 testingRound 2 testing

Customer target: 300 parts per edge

Date: 13-Mar-12 Operator:Customer: Engineer:Machine: Merritech 15-30 VNC Cell 1Coolant: no

Present GreenleafOperation: bottom faceInsert Manufacturer sumitomo GreenleafInsert: SNGX-434 SNGN-454Edge Prep: T2Grade: BNS800 GSN100Toolholder:

Insert Price ($): $88.00 $9.74 # edges/insert 8 8Price/ edge ($) $11.00 $1.22Passes/ edge 300 400Insert cost/ Pass $0.037 $0.003

Burden rate ($/hour) $60.00 $60.00Passes to finishing cut: 1.00 1.00

# of indexes/ day @ 20 pcs/hr 1.6 1.2Time to index (sec) 60 60Cost to index ($) $0.07 $0.05

Part Diameter (in.): 13.14 13.14speed (sfm) 2800 2800RPM (rev/min) 814 814DOC (in.) 0.1 0.1Feed (in/rev) 0.018 0.018LOC (in.) 4.471 4.471

removal rate (in3/min): 6.55 6.55Cut time for 1 pass(min): 0.31 0.31Cost to cut ($): $0.31 $0.31

Cost to cut 1 Pass: $0.41 $0.36Cost to complete all passes: $0.41 $0.36

Total cycle time (min): 0.33 0.33

Parts/Year 124,800Cost/Year $50,980.89 $44,704.75

Savings/year @ 1 spindle $6,276.14

Savings/year @ 6 spindles $37,656.84

Savings/year @ 1 spindle $18,828.42

Savings/year @ 6 spindles $112,970.52

INSERT JUSTIFICATION FOR TURNING

Total manufacturing at 20 parts/hr, 3 shifts, 5 days a week on 3 machining centers

INSERT COST PER PART

BURDEN RATE COST OF PART

based on 20 parts/hr, 3 shifts, 5 days a week, cell 1

DIA. RANGE 8.779-13.25

RPM VARIES DUE TO DIAMETER RANGE

Tool #6 – Finish Pilot.

Customer target: 300 parts per edge

Round 2 testingRound 2 testing

Date: 13-Mar-12 Operator:Customer: Engineer:Machine: Merritech 15-30 VNC Cell 1Coolant: no

Present GreenleafOperation: finish pilotInsert Manufacturer sumitomo GreenleafInsert: CNGX-434 CNGN-454Edge Prep: T9Grade: BNS800 GSN100Toolholder:

Insert Price ($): $88.00 $9.74 # edges/insert 8 8Price/ edge ($) $11.00 $1.22Passes/ edge 300 400Insert cost/ Pass $0.037 $0.003

Burden rate ($/hour) $60.00 $60.00Passes to finishing cut: 1.00 1.00

# of indexes/ day @20 pcs/hr 1.6 1.2Time to index (sec) 60 60Cost to index ($) $0.07 $0.05

Part Diameter (in.): 8.779 8.779speed (sfm) 2500 2500RPM (rev/min) 1088 1088DOC (in.) 0.06 0.06Feed (in/rev) 0.016 0.016LOC (in.) 0.53 0.53

removal rate (in3/min): 0.55 0.55Cut time for 1 pass(min): 0.03 0.03Cost to cut ($): $0.03 $0.03

Cost to cut 1 Pass: $0.13 $0.08Cost to complete all passes: $0.13 $0.08

Total cycle time (min): 0.06 0.05

Parts/Year 124,800

Cost/Year $16,696.53 $10,420.39

Savings/year @ 1 spindle $6,276.14

Savings/year @ 6 spindles $37,656.84

Savings/year @ 1 spindle $18,828.42

Savings/year @ 6 spindles $112,970.52

INSERT JUSTIFICATION FOR TURNING

Total manufacturing at 20 parts/hr, 3 shifts, 5 days a week on 3 machining centers

INSERT COST PER PART

BURDEN RATE COST OF PART

based on 20 parts/hr, 3 shifts, 5 days a week, cell 1

GSN-100 Ductile Iron Turning

GSN-100 Ductile Iron Turning

65-45-12 Ductile Iron, 30 R/C65-45-12 Ductile Iron, 30 R/C

Greenleaf WG-6218-2AGSN-100

• 1350 SFM (412 M/Min)• .0065 IPT (0,17 mm/tooth)• Machining 75 grooves/insert

Prior: Greenleaf WG-6218-2A HSN-100

• 1350 SFM (412 M/Min)• .0065 IPT (0,17 mm/tooth)• Machining 15 grooves/insert

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GSN-100 Cast Iron Milling

GSN-100 Cast Iron Milling

Gray Cast Iron, as cast

We are running:Milling Cutter- C404

Insert- CNGN-454 (CNGN120716)Two Nests are used so both the 80 and⁰ 100 corners of the Insert can be utilized⁰

Material – Gray Cast IronGrade- GSN-100 (GSN-100)DOC- .13- .19 (3.3- 4.8 mm)

Speed- 4,000- 5,000 SFM (1,220- 1,525 M/Min)

Feed- .0065-.0085 (.16- .22 mm) Fd/InsertCut time- approx. 80 minutes per Insert

index.A 3 reverse lead cartridge is used⁰

to circle interpolate Bores

GSN-100 Class 500 Gray Iron Milling

GSN-100 Class 500 Gray Iron Milling

Class 500 Gray Iron as castClass 500 Gray Iron as cast

Prior: Seco carbide APKT 16 MM Insert

• 625 SFM (190 M/Min)• .005 IPT (0,13 mm/tooth)• 11 Minutes cut time

• Greenleaf SNGN-434 (SNGN-120416) T2 GSN-100 • 3” Diameter C4 cutter

• 4000 SFM (1220 M/Min)• .005 IPT (0,13 mm/tooth)• 3 Minutes cut time

Ball Screw Housing

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GSN-100 Ductile Iron Milling

GSN-100 Ductile Iron Milling

Objective: To prove out GSN-100 as a replacement for HSN-200 in Ductile Iron Milling

Objective: To prove out GSN-100 as a replacement for HSN-200 in Ductile Iron Milling

• Material – Ductile Cast Iron:• Grade – HSN-200• DOC – .06” (1.52 mm) x 3 passes• Speed – 3000 SFM (915 M/Min)• Feed – .0045” (.11 mm) Actual Chip

thickness• Cutting time – 13.5 minutes• Parts – 90

• Material – Ductile Cast Iron:

• Grade – GSN-100

• DOC – .06” (1.52 mm) x 3 passes

• Speed – 3000 SFM (915 M/Min)

• Feed – .0045” (.11 mm) Actual Chip thickness

• Cutting time – 13.5 minutes

• Parts – 90

We are running:

Milling Cutter – CP-403R

Nest – XFNPS-8043

Insert – SPGN-434 T2A (SPGN120416)

GSN-100 DuctileGGG-50 Milling

GSN-100 DuctileGGG-50 Milling

GGG-50 Milling 290-350 BHNGGG-50 Milling 290-350 BHN

Other GSN-100Applications

Other GSN-100Applications

GSN-100 Jethete M152 Milling

GSN-100 Jethete M152 Milling

A 82% iron, 12% chromium material classified as a Martensitic Stainless Steel which has high

tensile strength and sufficient ductility at elevated temperatures as well as high corrosion

resistance. The material is very sensitive to heat during the machining process which

makes the material rapidly work harden. The application of Jethete M152 is mainly in high

stress gas turbine parts.

Jethete M152Jethete M152

Jethete M152 32-36 R/CJethete M152 32-36 R/C

Cutter: WSRP-60002 RH

Insert: RPGN-43 T1A HSN-200

Speed: 1500 SFM (458 M/Min)

Feed: .0033 IPT (.08 MM/tooth)

DOC: .050” (1.27 MM)

WOC: 2” (51 MM)

3 ½-4 minutes cut time, inserts showing flank wear, and experiencing heat in part

3 ½-4 minutes cut time, inserts showing flank wear, and experiencing heat in part

Jethete M152 32-36 R/CJethete M152 32-36 R/C

Cutter: WSRP-6001.2 RH

Insert: RPGN-43 T1A HSN-200

Speed: 1600 SFM (488 M/Min)

Feed: .0015 IPT (.04 MM/tooth)

DOC: .050” (1.27 MM)

WOC: 1.25” (31.8 MM)

4 minutes tool life, 37 % increase in feed over HSN-200’s best run!

4 minutes tool life, 37 % increase in feed over HSN-200’s best run!

Jethete M152 32-36 R/CJethete M152 32-36 R/C

Cutter: WSRP-6001.5 RH

Insert: RPGN-43 T1A GSN-100

Speed: 1600 SFM (488 M/Min)

Feed: .0028 IPT (.07 MM/tooth)

DOC: .050” (1.27 MM)

WOC: 1.5” (38.1 MM)

GSN-100 HRSA MillingGSN-100 HRSA Milling

GSN-100 42 R/C Age Hardened WaspaloyGSN-100 42 R/C Age Hardened Waspaloy

42 R/C age hardened Waspaloy42 R/C age hardened Waspaloy Cutters Inserts

FMRN-050R

FMRN-063R RNGN-45

FMRN-080R T2A

FMRN-100R

FMRP-5040R RPGN-43

FMRP-6340R T2A

From running all the tests it is apparent that we have a safe secure process with all sizes of cutters (both negative and positive) running at a feed rate of 0.0027”-0.0029”, (0.07mm-0.075mm) tooth. The surface speed is dependent on width of cut. (3000-3600 SFM/915-1100 SMM range)

GSN-100Stocking Program

GSN-100Stocking Program

GSN-100 Stocking ProgramGSN-100 Stocking Program

SNGN-433 T1A

SNGN-433 T2

SNGN-433 T2A

SNGN-434 T1A

SNGN-434 T2

SNGN-453 T2

SNGN-454 T2

SPGN-322 T1A

SPGN-434 T2A

TPGN-322 T2A

WG-6250-2A

WNGA-433 T2

ACHN-3222 T1A

ACHN-3422 T1A

CNGA-432 T2

CNGA-432 T2A

CNGA-433 T2

CNGA-434 T2

CNGA-434 T3A

CNGA-453 T2

CNGA-454 T2

CNGN-432 T2

CNGN-433 T2

CNGN-433 T9

CNGN-434 T2

CNGN-434 T2A

CNGN-453 T1A

CNGN-453 T2

CNGN-454 T1A

CNGN-454 T2

CNGN-454 T2A

CPGN-433 T2A

DNGA-432 T2

DNGA-433 T2

RPGN-2.52 T1

RPGN-2V T2

RPGN-32 T1

RPGN-3V T1A

RPGN-3V T2

RPGN-43 T1

RPGN-43 T1A

RPGN-43 T2A

RPGN-4V T2

SNGA-433 T2

SNGA-434 T2

SNGA-454 T2

RCGN-3V T1

RCGN-4V T1

RNGN-43 T2

RNGN-45 T1

RNGN-45 T1A

RNGN-45 T2

RNGN-45 T2A

RNGN-45A

ReviewReview

• Silicon Nitrides have their place in the high speed ceramic machining market.

•Grades such as Greenleaf GSN-100 work well in interrupted cutting and Milling operations due to Silicon Nitrides high thermal

shock resistance.

• Greenleaf GSN-100 works well in the machining of Gray, Ductile, and Nodular cast irons.

• Although developed for Cast Iron machining, Greenleaf GSN-100 works on other materials such as selected high temp alloys.

• You will want to start gearing your HSN customers to the new Greenleaf GSN-100.

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Questions?Questions?

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Thank You!