Drejeskær og -kvaliteter til stål
Uanset om du er på udkig efter skærkvaliteter til drejning i ubemandet produktion eller til specialfremstillede komponenter, har vi pålidelige skærkvaliteter, der tilbyder forudsigelig værktøjslevetid, høj maskinudnyttelsesgrad og den overfladekvalitet, som du har brug for.
Performance: Tool life
GC4405 vs. GC4305
| Component/segment: | Pin |
| Material: | Rolled, P2.5.Z.HT, 311 HB |
| Operation: | Continuous external axial and facing, roughing (emulsion) |
| Cutting data | ||
| vc, m/min (ft/min) | 331 (1086) | |
| fn, mm/rev (in/rev) | 0.35 (0.0138) | |
| ap, mm (inch) | 2 (0.0787) | |
| t, min (time in cut / component) | 2.1 | |
| GC4305 | New GC4405 | |
| Insert, ISO (ANSI) | CNMG 120412-PR (CNMG 433-PR) | CNMG 120412-PR (CNMG 433-PR) |
| Tool life, min | 21 | 48 |
| Reason for tool change | Risk of insert breakdown | Poor surface finish |
| Result: | Result: Grade GC4405 provided a 130% increase in tool life compared to existing grade GC4305 based on better plastic deformation and crater wear resistance. | |
Performance: Tool life
GC4405 vs. GC4305
| Component/segment: | Automotive |
| Material: | Cast, P2.1.Z.AN, 185 HB |
| Operation: | Continuous external axial and facing, roughing (emulsion) |
| Cutting data | ||
| vc, m/min (ft/min) | 280 (919) | |
| fn, mm/rev (in/rev) | 0.37 (0.015) | |
| ap, mm (inch) | 2 (0.079) | |
| t, min (time in cut / component) | 0.3 | |
| GC4305 | New GC4405 | |
| Insert, ISO (ANSI) | CNMG 120412-PM (CNMG 433-PM) | CNMG 120412-PM (CNMG 433-PM) |
| Tool life, min | 30 | 42 |
| Reason for tool change | Risk of insert breakdown | Risk of insert breakdown |
| Result: | Result: Grade GC4405 provided a 40% increase in tool life compared to existing grade GC4305 due to less crater wear. | |
Performance: Tool life
GC4405 vs. GC4305
| Component/segment: | Automotive transmission |
| Material: | Forged, P2.1.Z.AN, 174 HB |
| Operation: | Continuous external axial and facing, semi-finishing (emulsion) |
| Cutting data | ||
| vc, m/min (ft/min) | 320 (1050) | |
| fn, mm/rev (in/rev) | 0.32 (0.013) | |
| ap, mm (inch) | 1.5 (0.059) | |
| Q (MRR), cm3/min (in3/min) | 153.6 (9.37) | |
| GC4305 | New GC4405 | |
| Insert, ISO (ANSI) | DNMG 150608-PM (DNMG 442-PM) | DNMG 150608-PM (DNMG 442-PM) |
| Tool life, min | 50 | 66 |
| Reason for tool change | Poor surface finish | Poor surface finish |
| Result: | Result: Grade GC4405 provided a 33% increase in tool life versus GC4305. | |
Performance
Customer case: Automotive
| Component: | Steering component |
| Material: | Forged surface low alloy steel, P2.1.Z.AN, 125 HB |
| Operation: | External axial medium machining |
| Time in cut: | 15 s/component |
| Cutting data | ||
| vc, m/min (ft/min) | 113 (371) Note: spindle running 1800 RPM limit | |
| fn, mm/rev (in/rev) | 0.3 (0.012) | |
| ap, mm (inch) | 0.5 (0.020) | |
| Results | Existing grade GC4325 | New grade GC4415 |
| Insert | 3-80-101108-8-M5 | 3-80-101108-8-M5 |
| Tool life, pcs | 400 | 1150 |
| Reason for tool change | Tool life test | Tool life test |
Performance
Customer case: General engineering
| Component: | Pulling rail |
| Material: | Steel, P2.5.Z.HT, 330 HB |
| Operation: | Roughing |
| Cutting data | ||
| vc, m/min | 160 | 200 |
| fn, mm/rev | 0.35 | 0.5 |
| ap, mm | 3.25 | 3.25 |
| P10 competitor | Sandvik Coromant | |
| Insert, ISO (ANSI) | - | CNMG120412 (CNMG 433) -PR |
| Grade | - | GC4415 |
| MRR, cm3/min | 182 | 325 |
| Tool life, pcs | 14 | 30 |
| Reason for tool change | Predetermined no. of comp. | Predetermined no. of comp. |
| Result: | GC4415 significantly increased tool life and productivity. | |
Performance
Customer case: General engineering
| Component: | Hub |
| Material: | Forged 42CrMo4, CMC 02.2 MC, P2.5.Z.HT |
| Operation: | Continuous internal turning, wet machining |
| Cutting data | ||
| vc, m/min | 170 | 190 |
| fn, mm/rev | 0.51 | 0.51 |
| ap, mm | 5 | 5 |
| P15 competitor | Sandvik Coromant | |
| Insert, ISO (ANSI) | - | CNMG160616 (CNMG 544) -PR |
| Grade | - | GC4415 |
| MRR, cm3/min | 434 | 485 |
| Tool life, pcs | 4 | 11 |
| Result: | GC4415 provided reduced cycle time and an increased number of components per edge. | |
Performance
Customer case: Automotive
| Component: | Main shaft |
| Material: | Forged, P1.1.Z.AN (SAE 1026), 172 HB |
| Operation: | Continuous external cut of bars, roughing and semi-finishing |
| Cutting data | ||
| vc, m/min | 192 | |
| fn, mm/rev | 0.32 | |
| ap, mm | 1.2 | |
| P25 competitor | Sandvik Coromant | |
| Insert, ISO (ANSI) | - | TNMG160412 (TNMG 333) -PR |
| Grade | - | GC4425 |
| Tool life, pcs | 150 | 270 |
| Result: | The competitor insert has large crater wear, while GC4425 produced 80% more pieces with stable and predictable flank wear. | |
Performance
Customer case: General engineering
| Component: | Sleeve |
| Material: | S355J0 P.1.1.Z.AN, 220 HB |
| Operation: | External axial, facing |
| Cutting data | ||
| vc, m/min | 200 | |
| fn, mm/rev | 0.35 | |
| ap, mm | 1.5 | |
| P25 competitor | Sandvik Coromant | |
| Insert, ISO (ANSI) | - | CNMG120408 (CNMG 432) -PR |
| Grade | - | GC4425 |
| Tool life, pcs | 7 | 11 |
| Result: | The main wear is crater wear followed by flank wear on the trailing edge. GC4425 delivered 50% longer tool life with stable and predictable wear. | |
Performance
Customer case: General engineering
| Component: | Pressure roller |
| Material: | Machined, P1.4.Z.AN (19MnV6), 205 HB |
| Operation: | Continuous external axial, semi-finishing |
| Cutting data | ||
| vc, m/min | 200 | |
| fn, mm/rev | 0.4 | |
| ap, mm | 4.0 | |
| P25 competitor | Sandvik Coromant | |
| Insert, ISO (ANSI) | - | CNMG120408 (CNMG 432) -PR |
| Grade | - | GC4425 |
| Tool life, pcs | 12 | 18 |
| Result: | The competitor insert wore out due to plastic deformation. GC4425 worked 50% longer with stable and predictable wear. | |
Performance
Customer case: Automotive
| Component: | Automotive: Idler shaft |
| Material: | P1.2.Z.AN (C45) 207HB |
| Operation: | OD turning, light roughing |
| Cutting data | ||
| vc, m/min | 220 | |
| fn, mm/rev | 0.3 | |
| ap, mm | 3 | |
| P20 competitor | Sandvik Coromant | |
| Insert, ISO (ANSI) | - | TNMG160412 (TNMG 333) -PM |
| Grade | - | GC4415 |
| Time in cut, min | 0.13 | 0.13 |
| Tool life, pcs | 200 | 300 |
| Reason for tool change | Predetermined no. of comp. | Predetermined no. of comp. |
| Result: | Grade GC4415 provided a 50% increase in tool life compared to competitor grade. | |
Performance
Customer case: Power generation
| Component: | Axis |
| Material: | Rolled, P2.2.Z.AN, 258 HB |
| Operation: | Heavy roughing, external axial and facing using PrimeTurning™ |
| Cutting data | ||
| vc, m/min | 230 | |
| fn, mm/rev | 0.8 | |
| ap, mm | 2.7 | |
| Existing grade GC4325 | New grade GC4425 | |
| Insert, ISO (ANSI) | CP-B1108 (CP-B1108) -H3W | CP-B1108 (CP-B1108) -H3W |
| Grade | GC4325 | GC4425 |
| Time in cut, min | 1.28 | 1.28 |
| Tool life, pcs | 15 | 28 |
| Result: | The new GC4425 insert delivered a 90% tool life increase compared to existing grade. It provided secure machining with stable and predictable flank wear and no notch wear. | |
Performance
Customer case: General engineering
| Component: | Output shaft |
| Material: | Machined, P2.2.Z.AN (42CrMo4), 230 HB |
| Operation: | Continuous external axial, roughing |
| Cutting data | ||
| vc, m/min | 200 | |
| fn, mm/rev | 0.35 | |
| ap, mm | 2.0 | |
| Existing grade GC4325 | New grade GC4425 | |
| Insert, ISO (ANSI) | DNMG150612 (DNMG 433) -PM | DNMG150612 (DNMG 433) -PM |
| Grade | GC4325 | GC4425 |
| Tool life, pcs | 1.5 | 2 |
| Result: | The GC4325 insert wore out due to crater and flank wear. GC4425 worked longer with stable and predictable wear. | |
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