optimize productivity with advanced ceramic cutting tools · • advanced ceramic materials are now...
TRANSCRIPT
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© 2017 Greenleaf Corporation ‐ All rights reserved ‐ Proprietary and Confidential
Optimize Productivity with Advanced Ceramic Cutting Tools
Jan AnderssonGlobal Director, Tech Team and Marketing
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© 2017 Greenleaf Corporation ‐ All rights reserved ‐ Proprietary and Confidential
Today's Agenda1. For those of you who aren't familiar with us…
2. What are advanced ceramic cutting tools?
3. Ceramics: fact or fiction?
4. Metalcutting physics
5. Ceramic vs. carbide
6. Tool wear and tool life
7. Documented cost savings examples
8. Q & A
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© 2017 Greenleaf Corporation ‐ All rights reserved ‐ Proprietary and Confidential
Founded in 1945 by Walter Greenleaf, Sr.
Family owned and operated
Facilities in PA and NC
400+ employees
Sales in over 60 countries
Greenleaf Europe and Greenleaf China
Facilities in Saegertown, PA
Greenleaf Corporation designs and manufactures standard and special ceramic and carbide inserts and the supporting steel tooling.
Greenleaf Corp,Saegertown, PAISO 9001 Since 1994
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© 2017 Greenleaf Corporation ‐ All rights reserved ‐ Proprietary and Confidential
Delivering the most productive cutting tool solutions possible for our customers with the absolute best customer service
we can provide.
Core Values
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1945
1971
1973
1985
WG600
WG700
XSYTIN®‐1
A History of Continuous Innovation
1945
1971
1973
1985
WG‐600® XSYTIN®‐1
WG‐700™
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The effectiveness of productive effort, as measured in terms of the rate of output per unit of input
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Ceramics: Fact or Fiction?
1. Ceramics are brittle and lack predictability.2. Ceramics are applicable in limited and often specific
applications only.3. High heat required for ceramics damages the micro-
structure of the parent material.4. Traditionally high cutting speeds are required.5. Machines and setup must have maximum rigidity.6. Utilizing ceramics provides highly productive and
predictable processes.7. Care to share any others myths or facts?
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Metalcutting Physics
The four parameters of metalcutting:– Force– Stress– Thermal– Material
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Forces
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Forces
Axial
Radial
Tangential or Resultant
A + R ≈ T
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Roughing
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Medium to Finishing
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Classification of Greenleaf Ceramics
Super Alloys
Hardened Steel Machining
Cast Iron Machining
Oxide Ceramic(White) Al2O3
Black Ceramic
Al2O3 + TiC
Whisker-Reinforced
CeramicSilicon Nitride
GEM-19™ GEM-7™WG-300®WG-600®WG-700TM
GSN100™
Phase-Toughened
Ceramic
XSYTIN®-1
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What Are Whisker-Reinforced Ceramics?
• The basic concept involves reinforcing a hard ceramic matrix with extremely strong, stiff silicon carbide crystals, commonly called whiskers.
• The super-strong whiskers are dispersed into a matrix of fine-grained aluminum oxide adding tensile strength and improving the fracture toughness of the matrix.
• This creates a highly predictable cutting tool capable of withstanding extreme heat and abrasive conditions.
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What Are Phase-Toughened Ceramics?
• XSYTIN®-1 is a thermally stable whisker and particulate toughened silicon nitride with almost twice the strength of any other commercial ceramic tool from Greenleaf.
• The self reinforcing nature of this phase-toughened material gives it the ability to enhance productivity and provide predictable performance in applications that are novel for ceramics.
• Fine-grained, multi-phased structure provides ultra-high strength and wear resistance for demanding, high force cuts.
• XSYTIN®-1 has been engineered to be inherently fault tolerant, allowing it to continue to perform where other ceramics fail.
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Cutting Speed
(SFM
)
Carbide
WHISKER‐REINFORCED CERAMICSWG‐300®/WG‐600®/WG‐700™
Ceramic vs. Carbide Turning
PHASE‐TOUGHENED CERAMICSXSYTIN®‐1
Feed(IPT)
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WG-300®
Whisker-Reinforced vs. Phase-Toughened
XSYTIN®-1
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Comparable Strength
54,000 PSI 174,000 PSI100,000 PSI
WG‐300®WG‐600®WG‐700™ XSYTIN®‐1
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Tool Life vs. Feed Rate
Tool Life
Feed Rate
The increased strength of XSYTIN®-1 allows much higher feed rates.
X
Traditional Ceramics
TLmin
TLmaxFRopt
1.5‐2X
Phase‐ToughenedCeramics
FRopt
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Cutting Data and Tool LifeTool Life
Cutting Data
DOC
Fn
Vc
DOC
Fn
Vc
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Typical Tool Wear
Flank Wear Notching
Ceramic Tool Wear
Crater Wear
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Phase-Toughened vs. Traditional Ceramics
Whisker‐Reinforced SiAlON Phase‐Toughened
Speed
Feed
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How can ceramics reduce cycle times and increase cost
savings?
Let’s view a few case studies…
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Inconel 718 Turning (40 R/C)
CompetitorSiAlON ~ RNGN-45
Speed: 750 SFM
Feed: .010”/rev
DOC: .060”
GreenleafXSYTIN®-1 ~ RNGN-45
Speed: 922 SFM
Feed: .018”/rev
DOC: .060”
221% MRR increase = 101.3 minute cycle time reduction (>50%)$16,200 per year cost savings on one feature
0 2 4 6 8 10 12 14
Competitor
Greenleaf
MRR (in³/min)
0 50 100 150 200
Competitor
Greenleaf
Cycle Time (min)
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Stellite 6 Overlay Turning (60-62 R/C)
CompetitorCarbide ~ CNMM-544
Speed: 50 SFMFeed: .006”/rev
DOC: .028”
GreenleafXSYTIN®-1 ~ RNGN-45
Speed: 820 SFMFeed: .010”/rev
DOC: .047”
0 1 2 3 4 5
Competitor
Greenleaf
MRR (in³/min)
0 100 200 300 400
Competitor
Greenleaf
Cycle Time (Min)
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Stellite 6 Overlay Turning (60-62 R/C)
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Stellite 6 Overlay Turning (60-62 R/C)
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Stellite 6 Overlay Turning (60-62 R/C)
From 6 hours to 6 minutes per part!!$110,700 per year cost savings!
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GTD-111 Milling (40-42 R/C)
CompetitorSiAlON ~ RNGN-45
Speed: 2015 SFM
Feed: .002”/tooth
DOC: .100”
GreenleafXSYTIN®-1 ~ RNGN-43
Speed: 2788 SFM
Feed: .0035”/tooth
DOC: .100”
0 2 4 6 8 10 12 14
Competitor
Greenleaf
MRR (in³/min)
0 1 2 3 4 5 6 7
Competitor
Greenleaf
Cycle time (min)
5X MRR ~ 80% reduction in cycle time
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P20 Milling (30-32 R/C)
CompetitorCarbide ~ Square
Speed: 340 SFM
Feed: .0086”/rev
DOC: .375”
GreenleafXSYTIN®-1 ~ Square
Speed: 600 SFM
Feed: .013”/rev
DOC: .375”
2X parts/edge at 265% increase in productivity$290,000 per year cost savings
0 50 100 150
Competitor
Greenleaf
MRR (in3/min)
0 5 10 15
Competitor
Greenleaf
Cycle Time (hours)
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P20 Milling (30-32 R/C)
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• Today, only carbide• Some unsuccessful attempts to mill with ceramic
CGI Milling (compacted graphite iron)
Until now…
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CGI Milling (compacted graphite iron)
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Summary
• Advanced ceramic materials are now capable of machining more materials than ever before.
• Lower cutting speed capability enables the use of ceramics where not previously possible.
• More opportunity to utilize equipment once considered incapable of running ceramics.
• Ceramics greatly increase productivity, and hence cost savings, when applied correctly.
• Tremendous cost savings are being realized around the globe with the implementation of advanced ceramics.
Fact or fiction?
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