KMTL Cast Iron Turning Guide 32 65

Metallurgy and Machinability

32

Cast irons are iron-carbon-silicon alloys containinglarge amounts of carbon either as graphite or asiron carbide. They have higher carbon (>1.7%) and silicon (1.0-3.5%) contents than steel. Siliconpromotes dissociation of iron carbide to iron andgraphite. By increasing the silicon content in castiron, a greater proportion of graphite can beobtained at the expense of combined carbon.The microstructure and mechanical properties ofcast irons can be controlled not only by chemicalcomposition but also by cooling rate. Increasing thecooling rate will refine the graphite size as well asthe matrix structure and will increase strength andhardness. It also may increase the chilling tendency, which may increase the hardness butdecrease the strength.

Alloys within the broad group of cast irons includewhite iron, gray cast iron, mottled cast iron, malleable cast iron, and ductile cast iron. Each of these alloys may be modified by alloy additionsto obtain specific properties. Below are selectedASTM standards for different classes of cast irons.

Metallurgy Overview Machinability Overview

Machinability refers to the ease with which a workpiece can be machined and measured interms of tool life, metal removal rates, surface finish, ease of chip formation, or cutting forces.It is not an intrinsic property of a material, but is a result of complex interactions between themechanical properties of the workpiece, cuttingtools, lubricants used, and machining conditions.

Cast iron machinability varies greatly depending onthe type of iron and its microstructure. Ferritic castirons are easiest to machine, while white irons areextremely difficult to machine. Other grades of cast iron, such as malleable, ductile, compactedgraphite, and alloyed cast irons, are in between fer-ritic and white irons in ease of machinability.Additionally, hard spots in castings formed during rapid cooling and in presence of excessivelevels of carbide forming elements can seriouslydegrade machinability.

Alloy cast irons (ASTM A532, A518) can be classified as white cast irons, corrosion-resistantirons, and heat-resistant irons. Generally, they arebased on the iron (Fe) - carbon (C) - silicon (Si)system and contain one or more alloying elementsthat are added (>3%) to enhance one or more useful properties (corrosion resistance or strengthor oxidation resistance at elevated temperatures).Small amounts of ferrosilicon, cerium, or magnesium that are added to control the size,shape, and distribution of graphite particles arecalled inoculants, rather than alloying elements.Inoculation does not change the basic compositionor alter the properties of the constituents in themicrostructure. The alloyed irons for corrosionresistance are either 13-36% nickel (Ni) gray andductile irons (also called Ni-resist irons) or high silicon (~14.5% Si) gray irons. For elevated temperature service, nickel (Ni), silicon (Si), or aluminum (Al) alloyed gray and ductile irons are employed.

Selected ASTM Standards for Cast IronsUnalloyed Cast Irons

A47 Malleable iron castingsA48 Gray iron castingsA126 Gray iron castings for valves, flanges,

and pipe fittingsA159 Automotive gray iron castingsA197 Cupola malleable ironA220 Pearlitic malleable iron castingsA278 Gray iron castings for pressure-containment

with temperatures up to 345° C (650° F)A319 Gray iron castings for elevated temperatures –

non-pressure containing partsA395 Ferritic ductile iron pressure-retaining castings

for elevated temperaturesA476 Ductile iron castings for papermill dryer rollsA536 Ductile iron castingsA602 Automotive malleable iron castings

Low and Moderate Alloyed Cast Irons

A319 Gray iron castins for elevated temperatures for non-pressure – containing parts

A874 Ferritic ductile iron castings for low-temperature service parts

High-Silicon Cast Irons

A532 Abrasion-resistant cast irons

High-Nickel Austenitic Cast Irons

A436 Austenitic gray iron castingsA439 Austenitic ductile iron castings571 Austenitic ductile iron castings for pressure-

containing parts for low-temperature serviceFigure 1: Microstructure of white cast iron


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White cast irons, also known as abrasion-resistantcast irons, are an iron-carbon alloy in which the car-bon content exceeds 1.7%. White cast iron doesnot have any graphite in the microstructure.Instead, the carbon is present either as iron-carbide or complex iron-chromium carbides (Figure 1), which are responsible for high hardnessand resistance to abrasive wear. White iron showsa white, crystalline fracture surface because fracture occurs along the carbide plates. White ironcan be produced either throughout the section oronly on the surface by casting the molten metalagainst graphite or metal chill. In the latter case, it is referred to as chilled iron.

Corrosion-resistant cast irons obtain their resistance to chemical wear primarily from theirhigh alloy content of silicon, chromium, or nickel.Depending on which of the three alloys dominatesthe compositions, the corrosion-resistant materialcan be ferritic, pearlitic, martensitic, or austenitic.

Machinability – Alloy Cast Irons

White irons and corrosion-resistant high-silicon(14.5%Si) gray irons are the most difficult cast ironsto machine. Alloyed white irons such as nickel-hard(Ni-hard) alloys and high-silicon irons (ASTM A518)are generally ground to size or turned with a polycrystalline cubic boron nitride (PCBN) toolmaterial such as Kennametal grades KB9640,KD120, or KB5625

Gray cast irons (ASTM A48, A126, A159, ASMEAS278 and SAE J431) are named such becausetheir fracture has a gray appearance and consistsof graphite flakes embedded in a matrix of ferrite orpearlite, or a mixture of the two depending on thecomposition and cooling rate (Figures 2a-2d).Ferrite is a soft, low-carbon alpha iron phase withlow tensile strength but high ductility. Pearlite con-sists of lamellar plates of soft ferrite and hardcementite. Gray irons contain 2.5 to 4% carbon (C),1-3% silicon (Si), and manganese (Mn) (~0.1% Mnin ferritic gray irons and as high as 1.2% Mn inpearlitic gray irons). Sulfur (S) and phosphorus (P)may be present as residual impurities. Manganeseis deliberately added to neutralize the sulfur. Theresulting manganese sulfide is uniformly distributedin the matrix of gray iron as inclusions.

ASTM specification A48 classifies gray cast irons in terms of tensile strength (class 20 with 20 ksi

minimum tensile strength to class 60 with 60 ksiminimum tensile strength). The fluidity of liquid grayiron and its expansion during solidification due tothe formation of graphite are responsible for the economic production of shrinkage-free, intricate castings such as engine blocks. Most grayiron components are used in the as-cast condition.However, for specific casting requirements, theycan be heat treated (annealed, stress relieved, or normalized). Other heat treatments include hard-ening and tempering, austempering, martempering, and flame or induction hardening.

Figure 2a: Type C flakegraphite in gray iron

Figure 2b: Pearlite-ferritegray cast iron

Figure 2c: Coarse pearlite ingray cast iron

Figure 2d: Pearlitic gray cast iron

Machinability – Gray Cast Irons

Most gray cast irons are easier to machine thanother cast irons of similar hardness and virtually all steels. This is because the graphite flakes in themicrostructure act as chip breakers and serve as a lubricant for the cutting tool. Machining difficultiescan still occur in gray iron if chills are present in corners and thin sections or when sand isembedded in the casting surface. The material also shows a tendency to break out during exitfrom the cut. Although the graphite in cast ironimparts its free-machining characteristics, thematrix surrounding the graphite determines toollife. In fully annealed state, cast irons have a ferritic matrix and exhibit the best machinability.(While not as soft as ferrite in steel, the ferritic castiron shows better machinability than ferritic steeldue to the slight hardening effect of the dissolvedsilicon and the chip breaking and lubricating effectof the graphite.) As the ferrite content decreases

Photomicrographs courtesy of Buehler Ltd., Lake Bluff, Illinois, USA, www.buehler.com


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and pearlite increases, tool life decreases rapidly.Both iron and alloy carbides, when present aslarge particles, are detrimental to tool life. Ironswith higher phosphorous contents (~0.4%) form a hard constituent called steadite, which has adetrimental effect on tool life.

Gray cast irons are productively turned and milledwith multi-layered alumina and TiCN coatedinserts. The substrate tool material can be eithercarbide or silicon nitride-based ceramic. Cermetgrades such as KT315 are ideal for light depth-of-cut applications. A pure silicon nitride grade suchas KY3500 often yields the highest productivity on general turning and milling applications at highspeeds. Drilling applications are highly dependenton the drill geometry as well as drill grade.Kennametal solid carbide drills in the TF (tripleflute) and SE (sculptured edge) geometries inTiALN-coated grades KC7210 and KC7215 are the most desirable. For indexable insert drillingapplications, TiALN-coated KC7725 and aluminacoated KC7935 grades are the first choice for high-speed, high productivity applications.

Ductile (nodular) irons (ASTM A395, A476,A439, A536 and SAE J434), previously known as nodular iron or spheroidal-graphite cast iron,contain nodules of graphite embedded in a matrixof ferrite or pearlite or both (Figures 3a-3c). Thegraphite separates as nodules from molten ironduring solidification because of additives cerium(Ce) and magnesium (Mg) introduced in the molten

iron before casting. The nodules act as crackarresters and impart ductility to the material. Bycontrast, neither white iron nor gray iron shows asignificant amount of ductility. Ductile iron is ofhigher purity (low phosphorus [P] and sulfur [S])and is stronger than gray iron.

With a high percentage of graphite nodules present in the microstructure, the matrix determines the mechanical properties of ductileiron. Table B compares the composition of ductileiron with that of gray iron and malleable iron.

The ASTM classifies different grades of ductileirons in terms of tensile strength in ksi, yieldstrength in ksi, and elongation in percent. Forexample, ASTM A536 specifies five standard ductile iron grades: 60-40-18 / 65-45-12 (ferriticductile iron), 80-55-06 (ferritic-pearlitic ductile iron),100-70-03 (pearlitic ductile iron), and 120-90-02(quenched and tempered martensitic ductile iron).

Ferritic ductile iron — the ferrite matrix providesgood ductility and impact resistance and tensilestrength equivalent to low-carbon steel. Ferriticductile iron can be produced “as-cast” or may begiven an annealing treatment to obtain maximumductility and low-temperature toughness.

Ferritic-pearlitic ductile irons — usually produced in the “as cast” condition and featureboth ferrite and pearlite in the microstructure.Properties are intermediate between ferritic and pearlitic ductile irons.

Table B – Typical composition ranges for unalloyed cast irons

Figure 3a: Ferritic annealed ductile iron Figure 3b: Pearlite/ferrite ductile iron Figure 3c: Coarse lamellar pearlite inductile iron

materialtotal

carbonmanganese

silicon(Si)

chromium(Cr)

nickel(Ni)

molybdenum(Mo)

copper(Cu)

phosphorus(P)

sulfur(S)

cerium(Ce)

magnesium(Mg)

composition %

gray iron 3.25-3.50 0.50-0.90 1.80-2.30 0.05-0.45 0.05-0.20 0.05-0.10 0.15-0.40 0.12 max 0.15 max ... ...

malleable iron 2.45-2.55 0.35-0.55 1.40-1.50 0.04-0.07 0.05-0.30 0.03-0.10 0.03-0.40 0.03 max 0.05-0.07 ... ...

ductile iron 3.60-3.80 0.15-1.00 1.80-2.80 0.03-0.07 0.05-0.20 0.01-0.10 0.15-1.00 0.03 max 0.002 max 0.005-0.20 0.03-0.06


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Pearlitic ductile irons - the pearlitic matrix provides high strength, good wear resistance, and moderate ductility and impact resistance.

While the aforementioned three types of ductile ironare most common and used in as-cast condition, ductile irons also can be alloyed and/or heat-treated to provide additional grades as follows:

Martensitic ductile irons are produced using sufficient alloy additions to prevent pearlite formation, and a quench-and-temper heat treatmentto produce a tempered martensitic matrix. Thesematerials have a high strength and wear resistancebut lower levels of ductility and toughness. Bainiticductile irons are produced through alloying and/orby heat treatment to provide a hard, wear-resistantmaterial. Austenitic ductile irons are producedthrough alloying additions to provide good corrosionand oxidation resistance, magnetic properties, and strength and dimensional stability at high temperatures.

Machinability - Ductile Irons

The spherical graphite in ductile iron acts similar tothe flake graphite in gray iron in chip breaking andlubrication in machining. Machinability increaseswith silicon content up to 3%, but decreases significantly at higher silicon levels. As in the caseof gray cast iron, machinability decreases withincreasing pearlite content in the microstructure.Finer pearlite structures also decrease machinabili-ty. Still, pearlitic ductile irons are considered to havethe best combination of machinability and wearresistance. Cast irons with tempered martensiticstructure have a better machinability than pearlitewith similar hardness. Other microstructures suchas acicular bainite and acicular ferrite formed during heat treatment of ductile irons have machinability similar to martensite tempered to the same hardness. The higher tensile strength ofductile irons compared to gray cast iron requiresbetter rigidity within the machining system. Tool per-formance life may be slightly lower if run at gray cast iron surface speeds.

Ductile cast irons can be productively turned andmilled with multi-layered alumina and TiCN or PVDTiALN-coated inserts but at slightly slower speedsthan gray cast irons.

Malleable cast irons (ASTM A602 and A47)consist of uniformly dispersed and irregularly

shaped graphite nodules (often called “tempergraphite” because it is formed by the dissolution of cementite in the solid state) embedded in a matrix of ferrite, pearlite (Figure 4), or temperedmartensite. Malleable iron is cast as white iron and then heat-treated to impart ductility to an otherwise brittle material. Malleable iron possessesconsiderable ductility and toughness due to thenodular graphite and a lower carbon metallicmatrix. It has good fatigue strength and dampingcapacity, good corrosion resistance, good magneticpermeability, and low magnetic retention for magnetic clutches and brakes. Malleable iron, likemedium-carbon steel, can be heat treated to obtaindifferent matrix microstructures (ferrite, pearlite,tempered pearlite, bainite, tempered martensite, ora combination of these) and mechanical properties.

Malleable and gray irons differ in two respects: theiron carbide is partially or completely dissociated in malleable cast iron; the dissociation occurs onlywhen the alloy is solid. However, the dissociation ingray cast iron occurs during the early stages ofsolidification; hence the difference in the characterof graphite in each material.

Figure 4: Coarse pearlite in annealed malleable iron

Machinability – Malleable Cast Irons

The machinability of malleable iron is considered tobe better than that of free-cutting steel. Use low-strength ductile iron machining recommendations.

Austempered ductile irons (ADI) (ASTM A897-90)are used as cast, but some castings are heat treated to achieve desired properties. Austemperedductile irons are produced from conventional ductile iron through a special two-stage heat

Photomicrographs courtesy of Buehler Ltd., Lake Bluff, Illinois, USA, www.buehler.com


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treatment. The microstructure consists of spheroidal graphite in a matrix of acicular ferriteand stabilized austenite (called ausferrite) (Figure5). The fine-grained acicular ferrite provides anexceptional combination of high tensile strength withgood ductility and toughness. ADI can be given arange of properties through control of austemperingconditions. Compared to conventional grades ofductile iron, ADI offers twice the tensile strength fora given level of elongation.

Figure 5: Austempered ductile iron

Machinability – Austempered Ductile Irons

The machinability of the softer grades of austempered ductile iron (ADI) is equal or superiorto that of steels with equivalent strength. ADI can bemachined complete in the soft, as-cast state beforeheat treatment. This enables faster machine feedsand speeds and significantly increases tool life.

As the hardness of ADI increases, tool life decreases substantially. For this reason, only the 125/80/10 and 150/100/7 grades of ADI are machined after austempering. Processingsequence for parts processed to the higher strength:

• cast the component

• subcritically anneal to a fully ferritic matrix

• machine

• austemper

• finish machine (if required)

• finish operations (rolling, grinding, peening, if required)

Follow high-strength ductile iron recommendationsduring machining.

Compacted graphite iron (CGI) (ASTM A842)has a microstructure in which the graphite is interconnected like the flake graphite in gray castiron, but the graphite in CGI is coarser and morerounded (Figure 6). In other words, the structure ofCGI is between that of gray and ductile iron. Thegraphite morphology allows better use of thematrix, yielding higher strength and ductility thangray irons. The interconnected graphite in CGI provides better thermal conductivity and dampingcapacity than the spheroidal graphite in ductileiron. Although the CGI is less section-sensitivethan gray iron, high cooling rates are avoidedbecause of the high propensity of the CGI for chilling and high nodule count in thin sections.

Figure 6: Compacted graphite

Machinability – Compacted Graphite Iron

The graphite morphology in compacted graphiteiron enables chipbreaking but is strong enough toprevent powdery chip formations. This combinationis ideal for good machinability. As a result, themachinability of compacted graphite iron liesbetween that of gray iron and ductile iron for agiven matrix structure. Use low-strength ductile ironmachining recommendations.

Photomicrographs courtesy of Buehler Ltd., LakeBluff, Illinois, USA, www.buehler.com

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Gray Cast Irons & Gray, Austenitic

ASTM A436

Gray Cast Irons F10001 generally below MPa 207 (30 ksi) — Class l

F10002 at or above 207 MPa (30 ksi) — Class ll

F10003 generally at or above 276 MPa (40 ksi) — Class lll

F10004 124 MPa (18 ksi) min. 187 max G1800

F10005 173 MPa (25 ksi) min. 170-229 G2500

F10006 207 MPa (30 ksi) min. 187-241 G3000

F10007 241 MPa (35 ksi) min. 207-255 G3500

F10008 276 MPa (40 ksi) min. 217-269 G4000

F11401 138 MPa (20 ksi) min. 156 20 (A-C) 20

F11501 145 MPa (21 ksi) min. 156 Class A

F11701 172 MPa (25 ksi) min. 174 25 (A-C) 25

F12101 207 MPa (30 ksi) min. 210 30 (A-C) 30

F12102 214 MPa (31 ksi) min. 210 Class B

F12401 241 MPa (35 ksi) min. 212 35 (A-C) 35

F12801 276 MPa (40 ksi) min. 235 40 (A-C)

F12802 283 MPa (41 ksi) min. 235 Class C

F12803 276 MPa (40 ksi) min. 235 40

F13101 310 MPa (45 ksi) min. 250 45 (A-C)

F13102 310 MPa (45 ksi) min. 250 45

F13501 345 MPa (50 ksi) min. 265 50 (A-C)

F13502 345 MPa (50 ksi) min. 265 50

F13801 379 MPa (55 ksi) min. 282 55 (A-C)

F13802 379 MPa (55 ksi) min. 282 55

F14101 414 MPa (60 ksi) min. 302 60 (A-C)

F14102 414 MPa (60 ksi) min. 302 60

F14801 483 MPa (70 ksi) min. — 70

F15501 552 MPa (80 ksi) min. — 80

Gray, Austenitic F41000 172 MPa (25 ksi) min. 131-183 1

F41001 207 MPa (30 ksi) min. 149-212 1b

F41002 172 MPa (25 ksi) min. 118-174 2

F41003 207 MPa (30 ksi) min. 171-248 2b

F41004 172 MPa (25 ksi) min. 118-159 3

F41005 172 MPa (25 ksi) min. 149-212 4

F41006 138 MPa (20 ksi) min. 99-124 5

F41007 172 MPa (25 ksi) min. 124-174 6

Grade, Type or Number

ASTM A319

ASTM A278 &ASMEAS278

ASTM A159 &

SAE J431

ASTM A126

ASTM 48

hardnessHB

tensile strengthUNSmaterials


standard


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Grade, Type, or Number

Malleable Cast Irons & Pearlitic, Martensitic

Ductile Cast Iron & Ductile, Austenitic

Malleable

Cast Irons F20000 345 MPa (50 ksi) min. 220.5 MPa (32 ksi) min. 156 max. M3210

F20001 447.9 MPa (65 ksi) min. 309.7 MPa (45 ksi) min. 163-217 M4504

F20002 516.5 MPa (75 ksi) min. 345 MPa (50 ksi) min. 187-241 M5003



F20005 723.2 MPa (105 ksi) min. 586 MPa (85 ksi) min. 269-302 M8501

F22200 345 MPa (50 ksi) min. 224 MPa (32 ksi) min. 156 max. 32510

F22400 365 MPa (53 ksi) min. 241 MPa (35 ksi) min. 156 max 35018

Malleable, F22830 414 MPa (60 ksi) min. 276 MPa (40 ksi) min. 149-197 40010

Pearlitic & F23130 448 MPa (65 ksi) min. 310 MPa (45 ksi) min. 156-197 45008

Martensitic F23131 448 MPa (65 ksi) min. 310 MPa (45 ksi) min.; elongation 6% min. 156-207 45006

F23530 483 MPa (70 ksi) min. 345 MPa (50 ksi) min. 179-229 50005





ASTM A602 &

SAE J158

ASTM A220

ASTM A47

hardnessHB

tensile strength yield strengthUNSmaterials

Grade, Type, or Number

Ductile Cast Iron F30000 as required as req’d DQ & T

F32800 414 MPa (60 ksi) min. 276 MPa (40 ksi) min. 170 max. 60-40-18 D4018

F33100 448 MPa (65 ksi) min. 310 MPa (45 ksi) min. 156-217 65-45-12 D4512

F33101 414 MPa (60 ksi) min. 310 MPa (45 ksi) min. 190 5315 (A)


F34100 552 MPa (80 ksi) min. 414 MPa (60 ksi) min. 163 80-60-03 5316


F36200 827 MPa (120 ksi) min. 621 MPa (90 ksi) min. 270-350 120-90-02

Ductile, Austenitic F43000 400 MPa (58 ksi) min. 207 MPa (30 ksi) min. 139-202 D-2

F43001 400 MPa (58 ksi) min. 207 MPa (30 ksi) min. 148-211 D-2B

F43002 400 MPa (58 ksi) min. 193 MPa (28 ksi) min. 121-171 D-2C

F43003 379 MPa (55 ksi) min. 207 MPa (30 ksi) min. 139-202 D-3

F43004 379 MPa (55 ksi) min. 207 MPa (30 ksi) min. 131-193 D-3A



F43007 379 MPa (55 ksi) min. 207 MPa (30 ksi) min. 139-193 D-5B

F43010 448 MPa (65 ksi) min. 207 MPa (30 ksi) min. 121-171 D-2M-1, D-2M-2

F43020 379 MPa (50 ksi) min. 207 MPa (30 ksi) min. — (B)

F43021 345 MPa (50 ksi) min. 172 MPa (25 ksi) min. — (C)

MIL-I-24137

SAEJ434

AMSASTM A571

ASTM A439

ASTM A395A476A536

hardnessHB


standard

standard


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Austempered Ductile Iron (ADI)

Nickel (Ni) Hard / White Cast Iron

Compacted Graphite Iron (CGI)

Grade, Type, or

Number

Austempered n/a 850 MPa (125 ksi) min. 550 MPa (80 ksi) min./elongation 10% 269-321 125-80-10

Ductile Iron (ADI) n/a 1050 MPa (150 ksi) min. 700 MPa (100 ksi) min./elongation 7% 302-363 150-100-7

n/a 1200 MPa (175 ksi) min. 850 MPa (125 ksi) min./elongation 4% 341-444 175-125-4

n/a 1400 MPa (200 ksi) min. 1100 MPa (155 ksi) min./elongation 1% 388-477 200-155-1

n/a 1600 MPa (230 ksi) min. 1300 MPa (185 ksi) min. 444-555 230-185

standard

ASTM A897-90

hardnessHB


Austempered F45000 nickel-chromium irons 550-600 (I) A, Ni hard

Ductile Iron (ADI) F45001 nickel-chromium irons 550-600 (I) B, Ni hard

F45002 nickel-chromium irons 550-600 (I) C, Ni hard

F45003 nickel-chromium irons 400-600 (I) D, Ni hard

F45004 chromium-molybdenum irons 400-600 (II) A, white iron

F45005 chromium-molybdenum irons 400-600 (II) B, white iron

F45006 chromium-molybdenum irons 400-600 (II) C, white iron

F45007 chromium-molybdenum irons 400-600 (II) D, white iron

F45008 chromium-molybdenum irons 400-600 (II) E, white iron

F45009 chromium-molybdenum irons 400-600 (III) A, white iron

standard

ASTM A532 (class)

hardnessHB

propertiesUNSmaterials

Grade, Type, or

Number

Grade, Type, or

Number

Compacted n/a 250 MPa min. 175 MPa min./elongation 3% 179 Max. 250

Graphite Iron (CGI) n/a 300 MPa min. 210 MPa min./elongation 1.5% 143-207 300

n/a 350 MPa min. 245 MPa min./elongation 1.0% 163-229 350



standard

ASTM A842

hardnessHB



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UNS USA Australia Belgium Denmark France

Cast Iron Cross-Reference / Workpiece Comparison Table

Gray Cast Iron

ASTM 48, ASME SA278, ASTM A159, SAE J431

F10004 G1800

F10005 G2500

F10006 G3000

F10007 G3500

F10008 G4000

F11401 20-A T150 FGG10 GG10 FGL150

20 FGG15 GG15 FGL150A

F11701 25-A FGL200A

25 FGL250A

F12101 30-A T220 FGG20 GG20 FGL200

30

F12401 35-A FGG25 GG25 FGL250

35 FGL300A

F12801 40-A

F13101 45-A FGG30 GG30 FGL300

45 FGL350A

FGL400A

F13501 50-A FGG35 GG35 FGL350

50

F13801 55-A FGG40 GG40

50

F14101 60-A FGL400

60

Gray, Austenitic

ASTM A436

F41000 1 L-NiCuCr1562 L-NUC1562

F41001 1b L-NiCuCr1563 L-NUC1563

F41002 2 L-NiCr202 L-NC202

S-NiCr202

F41003 2b L-NC203

F41004 3 L-NiCr303

S-NiCr303

F41005 4 NiSiCr3055 L-NSC2053

L-NSC3055

F41006 5 L-Ni35 L-N35

S-NiCr353

F41007 6

Malleable Iron

ASTM 602, SAE J158, ASTM A7

F20000 M3210

M4504

M5003

M5503

M7002

M8501

F22200 32510

F22400 35018


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Gray Cast Iron

ASTM 48, ASME SA278, ASTM A159, SAE J431

Ch130 0212-00

Ch170 0215-00

0217-00

Ch190 0219-00

Ch210 0221-00

Ch230 0223-00

GG-10 100 100 G10 FC10-1 0110-00

150 150 FC15-2

GG-15 180 G15

GG-20 200 200 G20 FC20-3

220 250 G25 FC250-4

250

260

GG-25 FC25-4 0125-00

GG-30 300 300 G30 FC30-5

GG-35 350 350 G35 FC350-6

400

Gray, Austenitic

ASTM A436

GGL-NiCuCr1562 F1 L-NiCuCr1562

GGL-NiCuCr1563 F1 L-NiCuCr1563

GGL-NiCr202 F2 L-NiCr202 0523-00

L-NiCr202

GGL-NiCr203 F2 L-NiCr203

GGL-NiCr303 F3 L-NiCr303

GGL-NiSiCr3055 L-NiSiCr2053

L-NiSiCr3055

L-Ni35

S2

Malleable Iron

ASTM 602, SAE J158, ASTM A7

Germany Great Britain International Italy Japan Sweden


42

UNS USA Australia Belgium Denmark France

Cast Iron Cross-Reference / Workpiece Comparison Table

Ductile Cast Iron

ASTM A395, ASTM A476, ASTM A536, SAE J434

F32800 60-40-18 370-17 FNG38-17 715 FGS350-22

D4018 716 FGS350-22L

FGS400-15

FGS400-18

FGS400-18L

F33100 65-45-12 400-12 FNG42-12

D4512

F33101 5315

F33800 80-55-06 500-7 FNG50-7 727 FGS500-7

D5506

F34100 5316

F34800 100-70-03 700-0 FNG70-2 707 FGS700-2

D7003 800-2 FNG80-2 708 FGS800-2

F36200 120-90-02 FGA900-2

Ductile Cast Iron, Austenitic

ASTM A439

F43000 D-2 S-NC202

F43001 D-2B L-NiCr203 S-NC203

S-NiCr203

F43002 D-2C S-Ni22 S-N22

F43003 D-3 S-NC303

F43004 D-3A S-NiCr301 S-NC301

F43005 D-4 S-NiSiCr3055 S-NSC3055

F43006 D-5 S-Ni35 S-N35

F43007 D-5B S-NC353

D-5S

F43010 D-2M-1 S-NM234

D-2M-2


43

Ductile Cast Iron

ASTM A395, ASTM A476, ASTM A536, SAE J434

GGG-40 350/22 350-22 GS370-17 FCD37-0

350/22L40 350-22L FCD40-1 0717-00

400/18 400-15 0717-02

400/18L20 400-18 0717-15

400-18L

GGG-50 GS400-12 FDC45-2

GGG-60 500/7 500-7 GS500-7 FCD50-3 0727-02

FCD60-4

GGG-70 700/2 700-2 GS700-2 FCD70-5

800/2 800-2 GS800-2 FCD80-6

GGG-80 900/2 900-2

Ductile Cast Iron, Austenitic

ASTM A439

GGG-NiCr202 S2 S-NiCr202

S2W

GGG-NiCr203 S2B S-NiCr203

GGG-Ni22 S2C S-Ni22



GGG-NiSiCr3055 S-NiSiCr3055

GGG-Ni35 S-Ni35

GGG-NiCr353 S-NiCr353

GGG-NiMn234 S2M S-NiMn234

Germany Great Britain International Italy Japan Sweden

Expert Application Advisor – Cast Irons

44

Gray Cast Iron and Austenitic, Gray Iron (120-320 HB)ASTM: A48I: class 20, 25, 30, 35, 40, 45, 50, 55, 60ASTM: 126: class A, B, CASTM: A159 & SAE: J431; G1800, G2500, G3000, G3500, G4000ASTM: A436; 1, 1b, 2, 2b, 3, 4, 5, 6

Material Characteristics• out-of-balance condition may exist

• chucking on cast surface can be difficult

• tendency to break out during exit from cut

• contains abrasive elements; sand may beembedded in the cast surface

• potential for chatter on thin wall sections

• corners and thin sections can be chilled (hard and brittle)

• potential scale, inclusions

Common Tool Application ConsiderationsProblems & Solutionsexcessive edge wear

1. Use grade KC9315 or KT315 if running at moderate to high speeds.

2.. Use silicon nitride-based ceramic grades Kyon3500 or Kyon 1310, or PCBN grades, if runningat ultra-high speeds. Machining system musthave the rigidity and horsepower required torun at ultra-high speeds.

3. Increase the feed to reduce in-cut time.

chipping

1. Increase toolholder lead angle.

2. Use a grade with good edge strength, such as grade KC9325.

3. Ensure proper insert seating.

4. Use strong, negative-rake insert geometriessuch as MA, GX-T or GA-T.

5. Use inserts with an MT-land edge prep.

workpiece breakout

1. Use PVD-coated grade KC5010 at moderate to low speeds.

2. Reduce feed rate during exit.

3. Pre-chamfer casting edge at exit.


workpiece chatter

1. Use a smaller nose radius.

2. Apply insert geometries that are free-cutting,such as MG-FN and MG-RP.

3. Increase feed to stabilize workpiece.

4. Shorten toolholder or bar overhang.

5. Check toolholder and workholding system for rigidity.

6. Use Top Notch Turning (GX-T style) insert forincreased tooling rigidity.


45

Common Tool Application ConsiderationsProblems & Solutionsexcessive edge wear

1. Apply grade KC9315 to achieve higher speedsand longer tool life.

2. Use grade KC9325 for general purpose andinterrupted cutting.

3. Apply grade KC9315 or KT315 if edge wear isexcessive in smooth cuts.

4. Use ceramic grade Kyon 3400. Increase speedand make sure the machining set up and work-part clamping is rigid.

5. Increase feed to reduce time in cut.

crater wear

1. Apply grade KC9315 or KT315.

2. Reduce speed to lower the heat at cutting edge.

3. Apply ceramic grade Kyon 3400 when machining at high speeds.

4. Apply large amounts of flood coolant.

chipping

1. Use a strong negative-rake insert geometry.Apply the MX-T, GA-T, or MA insert geometryas a first choice; use MG-UN insert geometryas a second choice.

2. Select a T-land or large hone edge prep forgreater edge strength.


4. Reduce toolholder or boring bar overhang.

5. Ensure proper insert seating.

6. Apply grade KC9325.

7. Use grade KC9325, increase speed, anddecrease feed when cutting with interruptions.

8. Choose grade Kyon 3500 to replace Kyon 3400for heavy interruptions.

catastrophic failure

1. Reduce speed and feed.

2. Use a T-land plus hone edge prep.

torn or dull workpiece

1. Apply insert geometries that are free-cutting surface finish, such as the MG-FN.

2. Use a larger nose radius insert.

3. Use coated cermet grade KT315.

Ductile Iron (120-320 HB)ASTM: A395, A476, A536; 60-40-18, 65-45-12, 80-55-06, 80-60-03, 100-70-03, 120-90-02SAE: J434; DQ & T, D4018, D4512, D5506, D7003AMS: 5315, 5316ASTM: A439. A571; D2, D2B, D2C, D3, D3A, D4, D5, D5B, D2M

Material Characteristics• graphite is in spherical form, rather than flake

form customary in gray cast iron

• hard spots are common concentrations of carbide in the structure

• workpiece material structure may vary dramatically

• machining difficulties may develop from flankand crater wear on the tool

• higher tensile strength requires good rigidity in machining system

• decreased tool life should be expected, compared to machining gray or malleable cast iron

Malleable Cast Iron (120-320 HB)ASTM: A47: 32510, 35018ASTM: A602 & SAE J158; M3210, M4504, M5003, M5503, M7002, M8501ASTM: A220; 40010, 45008, 45006, 50005, 60004, 70003, 80002, 90001

Material Characteristics• graphite is in irregular-shaped nodules, rather

than flake form customary in gray cast iron• generally easy to machine at

aggressive conditions.


46

Austempered Ductile Iron (269-444 HB)ASTM: A897; 125-80-10, 150-100-7, 175-125-4, 200-155-1, and 230-185

Compacted Graphite Iron (CGI) (179-269 HB)ASTM: A842; Grade 250, 300, 350, 400, 450

Material Characteristics• graphite is in compacted (vermiform) shapes

and relatively free of flake graphite

• lower hardness levels than gray irons of equivalent strength

• hard or brittle enough to produce short chips;not hard enough to produce powder

Compacted graphite irons are machined similar tolower-strength ductile irons.

Material Characteristics• material is produced by heat treating

(austempering) high-quality ductile iron

• grades 200-155-1 and 230-185 are hard and not recommended for machining with carbide tooling

Austempered ductile irons machine similarly tohigh-strength ductile irons. Due to the higherstrength of these materials, tool life is shortenedcompared to conventional irons. Use high-strengthductile iron (>80 ksi) machining recommendationsfor these materials. See KENNA PERFECT recommendations on pages 6-13.

KM Kenclamp Tooling Catalog 2014• Our newest quick-release (1.5 turns) clamping design

• Robust clamping design reduces chatter and improves tool life

• Ensures insert repeatability and seating

• Fewer moving parts vs. competitive systems

Request A02-132!

Kennametal Tooling System Solutions

Failure Mechanism Analysis

47

*NOTE: Generally, inserts should be indexed when .030 flank wear is reached. If it is a finishing operation, index at .015 flank wear or sooner.

Edge Wear*

Corrective Action• Increase feed rate.• Reduce speed (sfm).

• Use more wear resistant grade.

• Apply coated grade.

Chipping

Corrective Action• Utilize stronger grade.• Consider edge

preparation.

• Check rigidity of system.

• Increase lead angle.

Heat Deformation

Corrective Action• Reduce speed.• Reduce feed.

• Reduce depth-of-cut(doc).

• Use grade with higher hot hardness.

Depth-of-Cut Notching

Corrective Action• Change lead angle.• Consider edge

preparation.

• Apply different grade.

• Adjust feed.

Thermal Cracking

Corrective Action• Properly apply

coolant.• Reduce speed.

• Reduce feed.• Apply coated grades.

Built-Up Edge

Corrective Action• Increase speed

(sfm).• Increase feed rate.

• Apply coated grades or cermets.

• Utilize coolant.• Edge prep

(smaller hone).

Crater

Corrective Action• Reduce feed rate.• Reduce speed (sfm).

• Apply coated grades or cermets.

• Utilize coolant.

Catastrophic Breakage

Corrective Action• Utilize stronger

insert geometry grade.

• Reduce feed rate.

• Reduce depth-of-cut (doc).

• Check rigidity of system.

Machinability Data – Cast Iron

48

Gray Cast Iron

The ideal turning insert geometry for machininggray cast iron should have the following characteristics:

• square or diamond shaped for maximum strength

• negative insert geometry for maximum strength and number of cutting edges

• minimum or no positive-rake chip-forming insert geometry for maximum edge strength

• medium edge hone on carbide inserts and a T-land edge prep on ceramic/sialon-gradeinserts

Pre-chamfer workpiece whenever possible to avoidworkpiece material breakout and interrupted cutshock damage to insert edge.

Ductile Cast Iron

The ideal turning insert geometry for machiningductile cast iron should have the following characteristics:

• square or diamond shaped for maximum strength

• negative insert geometry for maximum strengthand number of cutting edges

• positive-rake chip-forming insert geometry forfreer cutting action and chip control

• light edge hone on carbide inserts and a T-landedge prep on ceramic/sialon-grade inserts

Insert Edge Preparation

49

3. T-land plus hone

In aggressive applications, such as interrupted turning, chipping can occur at the intersection ofthe T-land and flank surface of the ceramic insert.This condition may be eliminated by applying asmall hone to the intersection while leaving theother attributes of the T-land unchanged.

Edge Preparation for Kennametal’s Advanced Cutting Tool Materials

Edge preparation is the term for the intentionalmodification of the cutting edge of an indexableinsert to enhance its performance in a metalcutting operation.

Ceramic cutting tool materials have a much higher hardness, but lower toughness, compared to conventional carbide materials. Because of this,ceramic materials have good bulk strength butlower edge strength versus carbide.

To optimize performance of ceramic cutting tools, it is critical that tool material, workpiece material,and machining conditions be considered relative toedge preparation. To achieve optimum edge preparation, make the minimum amount of modification necessary to distribute forces sufficiently enough to prevent chipping and catastrophic insert failure. Edge preparations forstandard inserts made with specific ceramic gradesare determined by target applications and listed inthe KENNA PERFECT insert selection system.

There are three choices of edge preparation forceramic materials:

1. T-land

2. hone

3. T-land plus hone

1. T-land

T lands protect the insert cutting edge by directingforces into the greater part of the insert, ratherthan to the smaller cross section of the sharpedge, during the metalcutting process. This helpsprevent chipping and catastrophic failure.

There is a tradeoff to the benefits of this edge preparation. Increasing the width “T” of the T-land orthe angle “A” increases the overall cutting forcesacting on the insert. This can negatively affect the wear rate of the insert and/or deformation of a thin-walled workpiece.

For most cast iron turning applications, use a T-landwidth smaller than the feed rate. For heavily interrupted turning, hard turning (workpiece >50HRC), and milling applications, use a T-land widthlarger than the feed rate.

2. Hone

Hones protect the insert cutting edge by eliminating the sharp edge and distributing the cutting forces over a larger area. Hones generallyare recommended for continuous or finishing operations; however, depending on the workpiecematerial, they can be used for interrupted or heavy cutting.

Chip Control Geometries

50

Kenloc Inserts

operation insert geometry

MG-MW

MM-RW(single sided)

insertstyle

application

MG-FW

MG-FN

wiper,

finishing

wiper,

medium

machining

wiper,

roughing

finishing

MG-RP

MG-RN

MM-RM(single sided)

MM-RH(single sided)

roughing

roughing

heavy

roughing

heavy

roughing

.008 - .016(0,2 - 0,4)

.010 - .080(0,3 - 2,0)

.012 - .024(0,3 - 0,6)

.030 - .200(0,8 - 5,1)

.010 - .050(0,3 - 1,3)

.050 - .500(1,3 - 12,7)

.005 - .012(0,1 - 0,3)

.010 - .100(0,3 - 2,5)

.010 - .025(0,3 - 0,6)

.045 - .250(1,1 - 6,4)

.010 - .025(0,3 - 0,6)

.045 - .250(1,1 - 6,4)

.010 - .040(0,3 - 1,0)

.050 - .500(1,3 - 12,7)

.015 - .050(0,4 - 1,3)

.050 - .500(1,3 - 12,7)

feed rate – inches.0015 .0025 .004 .006 .010 .016 .025 .040 .060 .100 .200

depth of cut – inches.004 .006 .010 .016 .025 .040 .060 .100 .160 .250 .500

feed rate – (mm)0,04 0,063 0,01 0,16 0,25 0,4 0,63 1,0 1,6 2,5 5,0

0,1 0,16 0,25 0,4 0,63 1,0 1,6 2,5 4,0 6,3 10,0depth of cut – (mm)

profile

MG-UNmedium

machining

.008 - .020(0,2 - 0,5)

.030 - .150(0,8 - 3,8)

Chip Control Geometries

51

Screw-On Inserts

operation insert geometry

MT-MW

insertstyle/

application

MT-FWwiper,

finishing

wiper,

medium

machining

profile

.003 - .013(0,1 - 0,3)

.008 - .060(0,2 - 1,5)

.005 - .020(0,1 - 0,5)

.016 - .130(0,4 - 3,3)

feed rate – inches.0015 .0025 .004 .006 .010 .016 .025 .040 .060 .100 .200

depth of cut – inches.004 .006 .010 .016 .025 .040 .060 .100 .160 .250 .500

feed rate – (mm)0,04 0,063 0,01 0,16 0,25 0,4 0,63 1,0 1,6 2,5 5,0

0,1 0,16 0,25 0,4 0,63 1,0 1,6 2,5 4,0 6,3 10,0depth of cut – (mm)

MT-11

MT-UF

fine

finishing

fine

finishing

.003 - .010(0,1 - 0,3)

.008 - .050(0,2 - 1,3)

.002 - .010(0,1 - 0,3)

.005 - .050(0,1 - 1,3)

MT-LF

MT-MF

finishing

medium

machining

.007 - .015(0,2 - 0,4)

.030 - .090(0,8 - 2,3)

.009 - .0170,2 - 0,4

.045 - .0901,1 - 2,3

Kennametal Grade System for Cutting Materials

52

Cermet – (CERamics with METallic binders)

KT315

C3K10 - K20

C7M10 - M20P10 - P20

composition: A multi-layered, PVD TiN/TiCN/TiN, coated cermet turning grade.application: Ideal for high-speed finishing to medium machining of most carbon and alloy steelsand stainless steels. Performs very well in cast and ductile iron applications too. Provides long andconsistent tool life and will produce excellent workpiece finishes.

grade coating composition and application C class ISO class

PVD Coated Carbide Grades

KC5010

C3K10 - K20

C4M10 - M20P10 - P20

composition: A PVD TiAlN coating over a very deformation-resistant unalloyed, carbide substrate.application: The KC5010 grade is ideal for finishing to general machining of most workpiece materials at higher speeds. Excellent for machining most steels, stainless steels, cast irons, non-ferrous materials and super alloys under stable conditions. It also performs well machining hardened and short chipping materials.


CVD Coated Carbide Grades

KC9315

KC9325

C3 - C4 K10 - K25

C2 - C3 K15 - K30

composition: A multi-layered CVD coating with a very thick K-MTCVD layer of TiCN, for maximum wear resistance, is applied over a substrate specifically engineered for cutting cast and ductile irons.application: The KC9315 grade delivers longer tool life when high-speed machining ductile and cast irons. The thick K-MTCVD TiCN coating ensures a tremendous tool life advantage, especially when cutting higher tensile strength ductile and cast irons where workpiece sizeconsistency and reliability of tool life are critical. This new Kennametal grade is excellent when used for either straight or lightly interrupted cut applications. Moreover, if you’re looking for high productivity performance, the KC9315 grade is an ideal choice.

composition: A TiCN and alumina-coated grade with a strong, reliable substrate.application: Grade development for the KC9325 grade focused on a variety of ductile and cast iron operations. The coating and substrate are optimized for flexibility. If you are machining different types of ductile or cast irons where application confidence, flexibility and broad range reliability are your primary requirements, the KC9325 grade is the perfect choice.


Silicon Nitride-Based Ceramic

KY1310*

KY3400

– K05-K15

C3 K10 - K30

composition: An advanced sialon ceramic grade.application: Grade KY1310 provides maximum wear resistance. Use it forhigh-speed continuous turning of gray cast iron, including through scale.

*KY1310 will be available January 2004.

composition: CVD coated pure silicon nitride grade.application: Excellent combination of toughness and edge wear resistance; used for general purpose machining of gray cast irons and ductile or nodular cast irons.

KY3500

C2K15 - K35M15 - M30

composition: Pure silicon nitride grade.application: Maximum toughness; used at high feed rates for rough machining of gray cast iron,including machining through interruptions.


PCBN – Polycrystalline Cubic-Boron Nitride

KB9640

C1 K05-K15

composition: A high CBN content, solid PCBN structure having multiple cutting edges and a CVDalumina coating.application: The KB9640 grade is applied in the roughing to semi-finishing of fully pearlitic graycast iron, chilled irons, high chrome alloy steels, sintered powdered metals, and heavy cuts in hard-ened steels (>45 HRC). Use for finished chilled cast iron and fully pearlitic cast iron. Do not apply onfinishing hardened steels. KB9640 can be applied effectively when roughing hardened steels.


Kennametal Grade System for Cutting Materials

53

KY3500“

Gray Cast Irons Ductile Cast Irons

Ceramic Cutting Tools Ceramic Cutting Tools

Carbide Cutting Tools Carbide Cutting Tools

54

ToolBoss™ System

No matter how intricate your metalworking manufacturing

operations or equipment, Kennametal’s new ToolBoss

System, powered by our exclusive, built-to-suit ATMS

software, will enable your machinists to spend more

time machining parts — far less energy locating tools.

KENNAMETALTOOL MANAGEMENT SOLUTIONS

www.kennametal.com

ToolBoss™ System

■ tool-buying costs by as much as 90%!

■ tool-inventory costs by up to 50%!

■ tool-supply costs by nearly 30%!

Our unique, new, easy-to-use/easy-to-audit tool dispensercan help reduce your:

55

Technical Information

page

Wiper Insert Application Guidelines . . . . . . . . . . . 56

Conversion Tables . . . . . . . . . . . . . . . . . . . . . . . . . 60

Nose Radius Selection for Surface Finish . . . . . . . . . . . 61

Insert Size Selection Guide . . . . . . . . . . . . . . . . . . . . . . 62

Tool Performance Report Form . . . . . . . . . . . . . . . . . . . . 63

Insert Identification System . . . . . . . . . . . . . . . . . . . . . . . . 66

Three Ways To Improve Your Turning Operations!

Conventional Turning Insertdoc ............0.050feed ..........0.012 iprspeed ........1,100 sfmfinish ........160 Ra (µin.)

Kennametal Wiper Technology –MWdoc ................0.050feed ................0.020 iprspeed..............1,100 sfmfinish ..............60 Ra (µin.)

Kennametal introduces three new geometries that are the latest in state-of-the-art turning technology. Our new -RW (Roughing Wiper), -MW (Medium Wiper) and -FW (Finishing Wiper) inserts employ a modified corner radius design that delivers a superior surface finish compared to conventional inserts. This technology allows you to choose the metalcutting benefit that’s most important to your application.

Double ProductivityKennametal’s new wiper geometries allow you to double your current feed rate and still achieve surface finishes comparableto conventional inserts. You’ll also see equivalent or better tool life using the appropriate KENNA PERFECT grade specificallydesigned for your workpiece material.

Better Workpiece FinishThese new wiper geometries also will give you a markedly improved surface finish at your current machining conditions. Under typical conditions, you’ll see as much as a 250% improvement in the workpiece surface finish, all with inserts that meet your corner radius specifications.

You choose! Either way, we’re sure you’ll agree that the new wiper geometries from Kennametal provide an outstanding way to optimize your turning operations. Please see the accompanying information for proper application guidelines.

56

Negative Wiper Inserts – Application Technology

57

Surface Finish

Theoretical Surface Finish – Raµ in. (µm)

1/2 IC23 41 63 91 120 160 200 250

—(0,6) (1) (1,6) (2,2) (3) (4) (5) (6,2)

— —

3/4 + 1 IC103 141 184 232 287 347 413

— — — —(2,6) (3,5) (4,6) (5,8) (7,2) (8,7) (10,3)

3/8 IC14 30 50 80

(0,3) (0,75) (1,3) (2)— — — — — — —

FW , MW, .008 .012 .016 .020 .024 .028 .032 .036 .040 .044 .048& RW (0,2) (0,3) (0,4) (0,5) (0,6) (0,7) (0,8) (0,9) (1) (1,1) (1,2)

insert feed rate – ipr (mm/rev)

Wiper Insert

How It Works

LEGENDf – feedr – corner radiusrw – wiper radiusRa – surface finish

Standard Insert

Corner Radius Configuration

CNMG and WNMG wiperinserts create a true cornerradius on the workpiece, justas a standard insert does.

DNMG and TNMG wiper inserts donot provide an exact corner radius onthe workpiece. The radius producedfalls within a ±.0025 tolerance band.(blue lines)

Negative Wiper Inserts – Application Technology

58

C– and W–Style Inserts Kenloc® Toolholders

Kenloc ToolholdersD– and T–Style Inserts

S–Style Inserts

CN . . 80° corner insert requires MCLN5° reverse lead angle toolholder

CN . . 100° corner insert requires MCRN15° lead angle toolholder

CN . . 100° corner insert requires MCKN15° lead angle toolholder

WN . . 80° corner insertrequires MWLN 5° reverse lead angle toolholder

DN . . 55° corner insert

requires MDJN 3° reverse

lead angle toolholder

TN . . 60° corner insert

requires MTJN 3° reverse

lead angle toolholder

Kenloc Toolholders

SN . . 90° corner insert

requires MSRN 15° lead

angle toolholder

NOTE: The holder guidelines above also apply to ceramic/PCBN wiper inserts in similar insert shapes; i.e.: CNGA, CNGX, DNGA, etc.

SN . . 90° corner insert

requires MSKN 15° lead

angle toolholder

surface with wiper effectsurface with standard insert edge

surface finish with wiper effectsurface with designated insert nose radiussurface finish with .016 radius

surface with wiper effectsurface with standard insert edge

Positive Wiper Inserts – Application Technology

59

-MWMedium

Machining Wiper

-FWFinishing Wiper

Positive geometry wiper inserts offer the sameadvantages as negative style inserts. Whencompared to conventional inserts, feed ratescan be doubled while maintaining surface finish, or surface finish can be improved by amultiple of 2.5 while maintaining productivefeed rates.

Surface Finish

Theoretical Surface Finish – Raµ in. (µm)

3/8 IC 1 4 8 14 22 30 39(0,02) (0,10) (0,20) (0,35) (0,55) (0,75) (1,00)

— — —

1/2 IC 1 2 6 10 16 24 31 39 51 63(0,02) (0,06) (0,15) (0,25) (0,40) (0,60) (0,80) (1,00) (1,30) (1,60)

1/4 IC 1 6 14 22 35 49(0,03) (0,15) (0,35) (0,55) (0,90) (1,25)

— — — —

FW , MW .002 .004 .006 .008 .010 .012 .014 .016 .018 .020

(0,05) (0,10) (0,15) (0,20) (0,25) (0,30) (0,35) (0,40) (0,45) (0,50)

insert feed rate – ipr (mm/rev)

CCMT and CPMT Inserts Screw-On Toolholders and Boring Bars

C.MT 80° inserts require 5° reverse lead

SCL toolholders.

SDN SDU

C.MT 100° inserts

require 15° lead

SCK toolholders.

D.MT 55° inserts require a 3° reverse lead angle and can be

used in SDN, SDU, and SDJ style toolholders and boring bars.

surface with wiper effectsurface with designated insertnose radius

SDJ

DCMT– and DPMT–Style Inserts

surface finish with wiper effectsurface with designated insert nose radiussurface finish with .016 radius

60

Conversion Charts

Brinell RockwellHB HRB HRC

Brinell RockwellHB HRB HRC

NOTE: Values in shaded areas are beyond normal range andgiven for information only.

654 — 60634 — 59615 — 58595 — 57577 — 56560 — 55543 — 54525 — 53512 — 52496 — 51481 — 50469 — 49455 — 48443 — 47432 — 46421 — 45409 — 44400 — 43390 — 42381 — 41371 — 40362 — 39353 — 38344 — 37336 109.0 36327 108.5 35319 108.0 34311 107.5 33301 107.0 32294 106.0 31286 105.5 30279 104.5 29271 104.0 28264 103.0 27258 102.5 26

253 101.5 25247 101.0 24243 100.0 23237 99.0 22231 98.5 21228 98.0 20222 97.0 18.6216 96.0 17.2210 95.0 15.7205 94.0 14.3200 93.0 13195 92.0 11.7190 91.0 10.4185 90.0 9.2180 89.0 8176 88.0 6.9172 87.0 5.8169 86.0 4.7165 85.0 3.6162 84.0 2.5159 83.0 1.4156 82.0 .30153 81.0 —150 80.0 —147 79.0 —144 78.0 —141 77.0 —139 76.0 —137 75.0 —135 74.0 —132 73.0 —130 72.0 —127 71.0 —125 70.0 —123 69.0 —

diameter Øinches mm

.315 8,0

.374 9,5

.394 10,0

.472 12,0

.500 12,7

.626 15,9

.630 16,0

.752 19,1

.787 20,0

.874 22,2

.984 25,01.000 25,41.260 32,01.500 38,11.968 50,02.000 50,82.480 63,02.500 63,5

speedsfm m/min.300 91400 122500 152600 183800 2441000 3051200 3662000 6104000 121910000 3048

diameter Øinches mm3.000 76,23.150 80,03.500 88,93.937 100,04.000 101,64.921 125,05.000 127,06.000 152,46.299 160,07.000 177,87.874 200,08.000 203,29.842 250,0

10.000 254,012.000 304,812.401 315,014.000 355,615.748 400,0

surface finish (Ra)µ inch µm

492 12,5248 6,3126 3,263 1,631 0,816 0,4

docinches mm

.010 0,254

.015 0,381

.030 0,762

.050 1,270

.100 2,540

.125 3,175

.150 3,810

.250 6,350

.375 9,525

.500 12,700

feedipr mm/rev

.003 .076

.005 .120

.005 .127

.006 .152

.007 .178

.008 .203

.009 .229

.010 .254

.011 .279

.012 .305

hardness inch to metric

Abbreviations

sfm = surface feet per minute

rpm = revolutions per minutempm = meters per minute

ipr = inches per revolutionipm = inches per minute

d = diameter

mm = millimeters

loc = length of cut

Turning Formulasto find formula

sfm d x rpm

3.82

rpm sfm x 3.82

d

mpm sfm ÷ 3.27

sfm mpm x 3.27

ipripm rpm

ipm ipr x rpm

mm inch x 25.4

inches mm ÷ 25.4

cut loc(minutes)time ipr x sfm

Application Guidelines – Cast Iron

Application Guidelines – Cast Iron

61

Nose Radius Selection and Surface Finish for Conventional Inserts*

Nose radius and feed rate have the greatest impacton surface finish. To determine the nose radiusrequired for a theoretical surface finish, use the following procedure and the chart above.

Locate the required surface finish (rms or AA)on the vertical axis.

Follow the horizontal line corresponding to thedesired theoretical finish to where it intersects the diagonal line corresponding to the intended feed rate.

Project a line downward to the nose radiusscale and read the required nose radius.

If this line falls between two values, choose the larger value.

• If no available nose radius will produce therequired finish, feed rate must be reduced.

• Reverse the procedure to obtain surface finish from a given nose radius.

*NOTE: See pages 57-59 for radius and surface finish specifications using wiper-style inserts.

NOTE: Peaks produced with a small radii insert (top) comparedto those produced with a large radius insert (bottom).

1

1

2

2

3

3

4

4

Insert Size Selection Guide

62

C-80° Diamond

D-55° Diamond

R-Round

S-Square

T-Triangle

V-35° Diamond

W-Trigon

Cast Iron Geometries

maximum depth of cut

cutting insert shape IC edge

length

.250 .250 .050

.375 .375 .075 .150

.500 .500 .120 .250 .250

.625 .625 .313 .313

.750 .750 .375 .375

1.000 1.000 .500 .500

.250 .275 .030

.375 .433 .060 .125 .150

.500 .590 .100 .175 .200

.625 .748

.375 .188 .112 .112

.500 .250 .200 .200

.625 .313 .250 .250

.750 .375 .300 .300

1.000 .500 .400 .400

.375 .375 ..075 .150 .150

.500 .500 ..120 .250 .250

.625 .625 .313 .313

.750 .750 .375 .375

1.000 1.000 .500 .500

.250 .433 .030

.375 .630 .060 .125 .150

.500 .866 .100 .175 .200

.625 1.060 .250 .300

.375 .630 .045 .060 .070

.500 .866 .120

.250 .157

.375 .236 .075 .100 .120

.500 .315 .100 .150 .200

finishing

MG-FNMG-FW

MA-T0820T0420-FW

general purposeMG-UNMG-RPMG-MW

roughingMX-T0820

..MA

– S0820

63

Turning Tool Performance Report

COMPANY & LOCATION DATE ENGINEER

CUSTOMER NAME MATERIAL TYPE AND CONDITION HARDNESS

PART DESCRIPTION CUTTING CONDITION (CIRCLE)

MACHINE & TYPE

OPERATION CONDITION OF MACHINE HP CONSTANT SFM ■■ YES ■■ NO

COMMENTS

PART CONFIGURATION

PERFORMANCE, TECHNICAL & COST DATA TEST 1 TEST 2 TEST 3

1 OPERATION NUMBER

2 TURRET POSITION

3 TOOLHOLDER

4 INSERT STYLE

5 GRADE

6 DEPTH OF CUT

7 LENGTH OF CUT

8 FEED RATE (IPR)

9 WORKPIECE DIAMETER

10 CUTTING SPEED RPM

SFM

11 CUTTING TIME PER PIECE (MINUTES) (30 SECONDS = .5)

12 PIECES PER EDGE

13 CUTTING TIME PER EDGE (MINUTES) (11 x 12)

14 CUTTING EDGES PER INSERT

15 PIECES PER INSERT (14 x 12)

16 REASONS FOR INDEXING

17 TYPE OF COOLANT

18 HORSEPOWER REQUIRED

19 FINISH (RMS)

20 CHIP CONTROL (GOOD, FAIR, POOR)

21 INSERT COST

22 INSERT COST PER PIECE (21 ÷ 15)

23 MACHINE COST PER HOUR

24 MACHINE COST PER PIECE (11 x 23 ÷60)

25 TOTAL COST PER PIECE (24 + 22)

26 ESTIMATED ANNUAL PRODUCTION – PIECES

27 ESTIMATED ANNUAL COST (26 x 25)

28 ESTIMATED ANNUAL SAVINGS

64

Steel

Stainless Steel

Cast Iron

Non-Ferrous Metals

High-Temperature Alloys

Hardened Materials

KENNA PERFECTInsertsKENNA PERFECTInserts

65

Table of Contents

page

Insert Identification System . . . . . . . . . . . . 66

Kenloc® Negative Inserts . . . . . . . . . . . . . . . . 68

Screw-On Inserts . . . . . . . . . . . . . . . . . . . . . . . 81

Top Notch® Turning Inserts . . . . . . . . . . . . . . . . . 91

Kendex® Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

KMTL Cast Iron Turning Guide 32 65

Documents

gray cast iron

malleable cast iron

cast iron machinability

ductile cast iron

white cast irons

mottled cast iron

grades of cast iron

white irons