McGraw-Hill Machining and Metalworking Handbook 3rd ed - R. Walsh_ D. Cormier (McGraw-Hill 2006) WW Part 6 potx

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Machining insert material types. The following describes currentlyavailable machining insert materials and their applications Thisinformation, together with the machining charts and remedies for

cutting or machining problems appearing in this section of the book, will enable you to select the proper type of insert and insert

Hand-material for specific machining applications and requirements mation courtesy of Valenite, Inc.)

(Infor-Uncoated carbide. This tungsten carbide–based material with acobalt binder, frequently alloyed with combinations of titaniumand tantalum carbides, is available in all ANSI and InternationalStandards Organization (ISO) grade groups for metal-cutting appli-cations These inserts cut all materials, including irons, steels, andsuperalloys; aluminum and brass alloys; and nonmetallics, includ-ing plastics, phenolics, and composites Applications range fromheavy roughing to finishing on almost all machining operations

CVD-coated carbide. This insert material is available in a completerange of grades, with substrates engineered for maximum compat-ibility with coatings Coatings include

These grades are excellent for machining most materials, includingcast irons, steels, stainless steels, and some superalloys—in turn-ing, boring, and milling operations

PVD-coated carbide. Inserts coated with a thin film (2 to 4 microns)

of titanium nitride (TiN) by physical vapor deposition (PVD) arecharacterized by good wear resistance, low coefficient of friction, andresistance to edge buildup PVD (TiN) coatings are applied at tem-peratures substantially below those used for chemical vapor deposi-tion (CVD), the process used most commonly for coating carbidecutting tools The result is less reaction with the substrate and thusbetter edge-strength retention Low coating temperatures allowgreater control over deposition rate and result in closer tolerancesand more grain-size control

Silicon nitride. This hot-pressed monolithic silicon nitride–basedceramic is designed to do one thing exceptionally well—cut cast

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iron materials It offers outstanding toughness and thermal tance and handles turning, boring, and milling operations at speedsfrom 350 to 5000 sfm Because Quantum 6 retains its hardness,toughness, and abrasion resistance at elevated temperatures, it canprovide excellent tool life at these speeds.

resis-PCBN. Polycrystalline cubic boron nitride (PCBN) inserts, able in both tipped and solid forms, are designed to machine ferrousworkpiece materials in the 40- to 70-RC range PCBN is signifi-cantly harder than cemented carbide or ceramic materials and isthe only material that combines a high degree of toughness withexceptional hot-hardness PCBN excels in turning of hardenedsteels, chilled and gray cast irons, and Ni-Hard materials

performance when cutting highly abrasive, low-tensile-strength,nonferrous, nonmetallic, and aluminum composite work materials.The exceptionally hard, wear-resistant diamond cutting tip retainsits sharpness even in demanding applications, running up to 7500sfm and beyond As a result, PCD inserts provide up to 100 timesthe tool life of carbide Excellent for roughing and high-speed fin-ishing on turning, boring, and milling operations

SpectraSystem coated carbide. Spectra-coated carbide grades representthe latest development in advanced coating technology and offerunique substrates for turning and milling This combination allowsSpectra-coated inserts to provide increased productivity at highercutting speeds with greater wear resistance over a broad range ofapplications and work materials Applications range from heavyroughing to precision finishing on work materials that include allsteels, stainless steels, many superalloys, and alloyed cast irons

Cermet. This type includes composite titanium carbide– and nium nitride–based materials designed for light roughing to high-speed finishing in turning, boring, and milling operations Thesegrades show excellent results on steels, stainless steels, cast irons,and aluminum They are capable of running at moderate to highspeeds and are best used with light feeds and depths of cut Theyfeature excellent abrasion resistance and thermal properties, aswell as lubricity for crater resistance

tita-Ceramic. Quantum 32 (Q32) is a metal oxide composite with edgestrength well suited for materials with hardness from 35 to 65 RC,

384 Chapter Seven

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