horn technology days 2015 - home » horn usa, inc ... · 3 stainless steels agenda focus: stainless...
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HORN Technology Days 2015
Technical presentation:
Grooving and parting off stainless materials
Speaker: Chris Foschaar
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Stainless steels
Agenda
Focus: Stainless steels
• Use, properties, categorization, machining process,
cutting edge requirements, geometry requirements
Machining examples based on various tool solutions
• Sleeve – Toolholder with clamping finger cooling
• Ring – Burr-free parting off and appropriate coating system
• Gearshaft – Insert with internal cooling
• Valve seat – Cartridge system 845
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Stainless steels
Usage
Industrial: Tanks, exhaust systems, screw connections, fittings, etc.
Domestic: Pots, knives, lamps, sinks, etc.
Construction: Structures, facades, roof coverings, swimming pools, etc.
Medical: Screws, plates, operating tools, etc.
Main features:
Corrosion resistance, mechanical toughness, durability, hygiene, aesthetic
appeal, appearance, etc.
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Stainless steels
Fe Fe
Fe Fe
Fe C
C
O2 O2
O2
Fe O Fe O Fe Fe O O
O2
O
O2
Fe Fe Fe
C C Cr
Cr
Cr
O2
O Cr
Properties – Corrosion resistance
Carbon steel Stainless steel
Free iron atoms combine with oxygen
to form iron oxide (rust).
Free chromium atoms combine with oxygen
to form chromium oxide (passive layer).
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Stainless steels
Categorization
Ferritic
structure
e.g. 1.4511
Austenitic-ferritic
structure
e.g. 1.4462
Austenitic
structure
e.g. 1.4301 (V2A)
1.4571 (V4A)
Martensitic
structure
e.g. 1.4313
Source: Informationsstelle Edelstahl Rostfrei
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Ferritic corrosion-resistant steels
Main alloying component: Cr
Use:
Fittings, cladding, apparatus construction, machine
elements, silos, tanks and vehicle bodies
Properties:
Good non-cutting forming properties (can be cold-
formed), weldable, difficult to machine
Exhaust systems
Stainless steels
Source: Informationsstelle Edelstahl Rostfrei
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Martensitic and precipitation-hardening stainless steels
Main alloying component: Cr, C (carbon martensite)
or Ni (nickel martensite)
Use:
Axles, shafts, screws, surgical
instruments, rolling bearings, production materials,
springs and cutting tools
Properties:
Can be hardened, easy to machine, limited
weld-ability, high strength
Razor blades
Stainless steels
Source: Informationsstelle Edelstahl Rostfrei
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Elevator tower made from duplex
pipes
Austenitic-ferritic stainless steels (duplex steels)
Main alloying component: Cr, Ni, Mo
Use:
Offshore platforms, aviation industry
Properties:
Weldable, highly corrosion-resistant
Stainless steels
Source: Informationsstelle Edelstahl Rostfrei
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Austenitic corrosion-resistant steels
Main alloying component: Cr, Ni, Mo, manganese in the case of manganese
austenite
Use:
Food, pharmaceutical and cosmetics industries,
chemical apparatus construction, vehicle construction, domestic,
surgical instruments and sanitation
Properties:
Can be cold-formed and welded with ease, difficult to machine
Submersible pump
Stainless steels
Source: SPECK
Pumpen
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Geometry requirements
Low cutting edge rounding
Small protective chamfer
Large chipping/relief angle
Medium chip tapering
For low to medium feed rates
Stainless steels
E.g.: 3V geometry with internal cooling
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Stainless steels
Machining example: Sleeve
Workpiece:
Sleeve from X5CrNi18-10 (1.4301)
Rm = 500-700 N/mm²
Machine:
STAR SR-32J Swiss-type lathe
80 bar, emulsion
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Tool:
Toolholder:
LH100.1616.0.23.IK
Cutting insert:
S100.0300.3V2 AS45
Stainless steels
Internal cooling through
clamping finger
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Cutting data:
vc = 140 m/min
f = 0.12 mm/rev
Stainless steels
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Stainless steels
Result:
Three times the tool life in pieces
Competition with internal cooling
max. 150 parts per cutting edge
HORN with internal cooling
450 parts per cutting edge 0
100
200
300
400
500
Competition HORN
Part
s
Tool life
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Stainless steels
Machining example: Ring
Workpiece:
Ring made of X5CrNi18-10 (1.4301)
External Ø 32 mm, wall thickness 2 mm
Rm = 500-700 N/mm²
Challenges:
Raw material: welded pipe (Tube)
Extreme batch fluctuations
Burr-free parting off
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Stainless steels
Tools:
Standard indexable insert
R312.0510.00 TN35
Custom insert
114.0020.4646 TN35
PH35
PH35
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Stainless steels
Machine:
Index GB65
Flood cooling with emulsion
Cutting data:
vc = 150 m/min
f = 0.03 mm/rev
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Stainless steels
Result:
Burr-free components
Tool life in pieces tripled in
comparison to TN35
0
2000
4000
6000
TN3 PH3
Part
s
Tool life
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Machining example: Gearshaft
Workpiece:
Gearshaft made of
X2CrNiMo17-12-2 (1.4404)
Rm = 700 N/mm²
Machine:
Gildemeister CTX Beta 1250 4A
with VDI40 holder,
25 bar, emulsion
Stainless steels
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Stainless steels
Complete tool:
Insert: S100.0300.3V2.IK HP65
Internal cooling through insert
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Parting off from Ø 65 mm to 0
Cutting data:
vc = 130 m/min (nmax = 1400 rpm)
f1 = 0.08 mm/rev up to Ø 3 mm
f2 = 0.02 mm/rev up to X -0.5 mm
Stainless steels
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Stainless steels
Result:
2.7 times tool life in pieces
compared with competition
Competition: 15 parts per cutting
edge
HORN: 40 parts per cutting edge 0
10
20
30
40
50
Competition HORN
Part
s
Tool life
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Stainless steels
Machining example: Valve seat
Workpiece:
Valve seat from X17CrNi16-2 (1.4057)
Rm = 950 N/mm²
Machine:
Miyano ABX 64, emulsion
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Stainless steels
Complete tool:
Base carrier: 845.0000.0102
Cartridge: LNK100.0845.34.4.73.IK
Insert: S100.0300.3V2 HP65
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Stainless steels
Parting off Ø 28 mm
Cutting data:
vc = 170 m/min
f = 0.08 mm/rev
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Stainless steels
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Summary
Categorization, properties and machining process of stainless steels
Machining examples based on various tool systems
• H100 with internal cooling through clamping finger
• Special insert 114 – PH3 coating
• Parting off – S100 with internal cooling – 3V geometry
• 845 cartridge interface
Stainless steels
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Thank you for your attention!
Stainless steels