Metallurgy and Machinability
Metallurgy Overview
Machinability Overview
Cast irons are iron-carbon-silicon alloys containing
large amounts of carbon either as graphite or as
iron carbide. They have higher carbon (>1.7%)
and silicon (1.0-3.5%) contents than steel. Silicon
promotes dissociation of iron carbide to iron and
graphite. By increasing the silicon content in cast
iron, a greater proportion of graphite can be
obtained at the expense of combined carbon.
The microstructure and mechanical properties of
cast irons can be controlled not only by chemical
composition but also by cooling rate. Increasing the
cooling rate will refine the graphite size as well as
the matrix structure and will increase strength and
hardness. It also may increase the chilling
tendency, which may increase the hardness but
decrease the strength.
Machinability refers to the ease with which a
workpiece can be machined and measured in
terms 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 the
mechanical properties of the workpiece, cutting
tools, lubricants used, and machining conditions.
Alloys within the broad group of cast irons include
white iron, gray cast iron, mottled cast iron,
malleable cast iron, and ductile cast iron. Each
of these alloys may be modified by alloy additions
to obtain specific properties. Below are selected
ASTM standards for different classes of cast irons.
Selected ASTM Standards for Cast Irons
Unalloyed Cast Irons
A47
A48
A126
A159
A197
A220
A278
A319
A395
A476
A536
A602
Malleable iron castings
Gray iron castings
Gray iron castings for valves, flanges,
and pipe fittings
Automotive gray iron castings
Cupola malleable iron
Pearlitic malleable iron castings
Gray iron castings for pressure-containment
with temperatures up to 345° C (650° F)
Gray iron castings for elevated temperatures –
non-pressure containing parts
Ferritic ductile iron pressure-retaining castings
for elevated temperatures
Ductile iron castings for papermill dryer rolls
Ductile iron castings
Automotive malleable iron castings
Low and Moderate Alloyed Cast Irons
A319
A874
Gray iron castins for elevated temperatures for
non-pressure – containing parts
Ferritic ductile iron castings for low-temperature
service parts
Cast iron machinability varies greatly depending on
the type of iron and its microstructure. Ferritic cast
irons are easiest to machine, while white irons are
extremely difficult to machine. Other grades of
cast iron, such as malleable, ductile, compacted
graphite, and alloyed cast irons, are in between ferritic and white irons in ease of machinability.
Additionally, hard spots in castings formed
during rapid cooling and in presence of excessive
levels of carbide forming elements can seriously
degrade machinability.
Alloy cast irons (ASTM A532, A518) can be
classified as white cast irons, corrosion-resistant
irons, and heat-resistant irons. Generally, they are
based on the iron (Fe) - carbon (C) - silicon (Si)
system and contain one or more alloying elements
that are added (>3%) to enhance one or more
useful properties (corrosion resistance or strength
or 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 are
called inoculants, rather than alloying elements.
Inoculation does not change the basic composition
or alter the properties of the constituents in the
microstructure. The alloyed irons for corrosion
resistance are either 13-36% nickel (Ni) gray and
ductile 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.
High-Silicon Cast Irons
A532
Abrasion-resistant cast irons
High-Nickel Austenitic Cast Irons
A436
A439
571
32
Austenitic gray iron castings
Austenitic ductile iron castings
Austenitic ductile iron castings for pressurecontaining parts for low-temperature service
Figure 1: Microstructure of white cast iron
Metallurgy and Machinability
White cast irons, also known as abrasion-resistant
cast irons, are an iron-carbon alloy in which the carbon content exceeds 1.7%. White cast iron does
not have any graphite in the microstructure.
Instead, the carbon is present either as ironcarbide or complex iron-chromium carbides
(Figure 1), which are responsible for high hardness
and resistance to abrasive wear. White iron shows
a white, crystalline fracture surface because
fracture occurs along the carbide plates. White iron
can be produced either throughout the section or
only on the surface by casting the molten metal
against 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 their
high alloy content of silicon, chromium, or nickel.
Depending on which of the three alloys dominates
the compositions, the corrosion-resistant material
can be ferritic, pearlitic, martensitic, or austenitic.
minimum tensile strength to class 60 with 60 ksi
minimum tensile strength). The fluidity of liquid gray
iron and its expansion during solidification due to
the formation of graphite are responsible
for the economic production of shrinkage-free,
intricate castings such as engine blocks. Most gray
iron components are used in the as-cast condition.
However, for specific casting requirements, they
can be heat treated (annealed, stress relieved,
or normalized). Other heat treatments include hardening and tempering, austempering,
martempering, and flame or induction hardening.
Figure 2a: Type C flake
graphite in gray iron
Figure 2b: Pearlite-ferrite
gray cast iron
Figure 2c: Coarse pearlite in
gray cast iron
Figure 2d: Pearlitic gray
cast iron
Machinability – Alloy Cast Irons
White irons and corrosion-resistant high-silicon
(14.5%Si) gray irons are the most difficult cast irons
to 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) tool
material such as Kennametal grades KB9640,
KD120, or KB5625
Gray cast irons (ASTM A48, A126, A159, ASME
AS278 and SAE J431) are named such because
their fracture has a gray appearance and consists
of graphite flakes embedded in a matrix of ferrite or
pearlite, or a mixture of the two depending on the
composition and cooling rate (Figures 2a-2d).
Ferrite is a soft, low-carbon alpha iron phase with
low tensile strength but high ductility. Pearlite consists of lamellar plates of soft ferrite and hard
cementite. Gray irons contain 2.5 to 4% carbon (C),
1-3% silicon (Si), and manganese (Mn) (~0.1% Mn
in ferritic gray irons and as high as 1.2% Mn in
pearlitic gray irons). Sulfur (S) and phosphorus (P)
may be present as residual impurities. Manganese
is deliberately added to neutralize the sulfur. The
resulting manganese sulfide is uniformly distributed
in the matrix of gray iron as inclusions.
ASTM specification A48 classifies gray cast irons
in terms of tensile strength (class 20 with 20 ksi
Machinability – Gray Cast Irons
Most gray cast irons are easier to machine than
other cast irons of similar hardness and virtually
all steels. This is because the graphite flakes in the
microstructure act as chip breakers and serve as
a lubricant for the cutting tool. Machining difficulties
can still occur in gray iron if chills are present
in corners and thin sections or when sand is
embedded in the casting surface. The material
also shows a tendency to break out during exit
from the cut. Although the graphite in cast iron
imparts its free-machining characteristics, the
matrix surrounding the graphite determines tool
life. 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 cast
iron shows better machinability than ferritic steel
due to the slight hardening effect of the dissolved
silicon and the chip breaking and lubricating effect
of the graphite.) As the ferrite content decreases
Photomicrographs courtesy of Buehler Ltd., Lake Bluff, Illinois, USA, www.buehler.com
33
Metallurgy and Machinability
and pearlite increases, tool life decreases rapidly.
Both iron and alloy carbides, when present as
large particles, are detrimental to tool life. Irons
with higher phosphorous contents (~0.4%) form
a hard constituent called steadite, which has a
detrimental effect on tool life.
iron before casting. The nodules act as crack
arresters and impart ductility to the material. By
contrast, neither white iron nor gray iron shows a
significant amount of ductility. Ductile iron is of
higher purity (low phosphorus [P] and sulfur [S])
and is stronger than gray iron.
Gray cast irons are productively turned and milled
with multi-layered alumina and TiCN coated
inserts. The substrate tool material can be either
carbide or silicon nitride-based ceramic. Cermet
grades such as KT315 are ideal for light depth-ofcut applications. A pure silicon nitride grade such
as KY3500 often yields the highest productivity
on general turning and milling applications at high
speeds. Drilling applications are highly dependent
on the drill geometry as well as drill grade.
Kennametal solid carbide drills in the TF (triple
flute) and SE (sculptured edge) geometries in
TiALN-coated grades KC7210 and KC7215 are
the most desirable. For indexable insert drilling
applications, TiALN-coated KC7725 and alumina
coated KC7935 grades are the first choice for
high-speed, high productivity applications.
With a high percentage of graphite nodules
present in the microstructure, the matrix
determines the mechanical properties of ductile
iron. Table B compares the composition of ductile
iron with that of gray iron and malleable iron.
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 matrix
of ferrite or pearlite or both (Figures 3a-3c). The
graphite separates as nodules from molten iron
during solidification because of additives cerium
(Ce) and magnesium (Mg) introduced in the molten
Figure 3a: Ferritic annealed ductile iron
The ASTM classifies different grades of ductile
irons in terms of tensile strength in ksi, yield
strength in ksi, and elongation in percent. For
example, ASTM A536 specifies five standard
ductile iron grades: 60-40-18 / 65-45-12 (ferritic
ductile 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 provides
good ductility and impact resistance and tensile
strength equivalent to low-carbon steel. Ferritic
ductile iron can be produced “as-cast” or may be
given an annealing treatment to obtain maximum
ductility and low-temperature toughness.
Ferritic-pearlitic ductile irons — usually
produced in the “as cast” condition and feature
both ferrite and pearlite in the microstructure.
Properties are intermediate between ferritic
and pearlitic ductile irons.
Figure 3b: Pearlite/ferrite ductile iron
Figure 3c: Coarse lamellar pearlite in
ductile iron
Table B – Typical composition ranges for unalloyed cast irons
composition %
material
gray
iron
malleable
iron
ductile
iron
34
total
carbon
silicon
(Si)
chromium
(Cr)
nickel
(Ni)
manganese
molybdenum
(Mo)
copper
(Cu)
phosphorus
(P)
sulfur
(S)
cerium
(Ce)
magnesium
(Mg)
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
...
...
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
...
...
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
Metallurgy and Machinability
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 iron
are most common and used in as-cast condition,
ductile irons also can be alloyed and/or heattreated 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 treatment
to produce a tempered martensitic matrix. These
materials have a high strength and wear resistance
but lower levels of ductility and toughness. Bainitic
ductile irons are produced through alloying and/or
by heat treatment to provide a hard, wear-resistant
material. Austenitic ductile irons are produced
through alloying additions to provide good corrosion
and oxidation resistance, magnetic properties,
and strength and dimensional stability at
high temperatures.
Machinability - Ductile Irons
The spherical graphite in ductile iron acts similar to
the flake graphite in gray iron in chip breaking and
lubrication in machining. Machinability increases
with silicon content up to 3%, but decreases
significantly at higher silicon levels. As in the case
of gray cast iron, machinability decreases with
increasing pearlite content in the microstructure.
Finer pearlite structures also decrease machinability. Still, pearlitic ductile irons are considered to have
the best combination of machinability and wear
resistance. Cast irons with tempered martensitic
structure have a better machinability than pearlite
with similar hardness. Other microstructures such
as 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 of
ductile irons compared to gray cast iron requires
better rigidity within the machining system. Tool performance life may be slightly lower if run at
gray cast iron surface speeds.
Ductile cast irons can be productively turned and
milled with multi-layered alumina and TiCN or PVD
TiALN-coated inserts but at slightly slower speeds
than gray cast irons.
Malleable cast irons (ASTM A602 and A47)
consist of uniformly dispersed and irregularly
shaped graphite nodules (often called “temper
graphite” because it is formed by the dissolution
of cementite in the solid state) embedded in a
matrix of ferrite, pearlite (Figure 4), or tempered
martensite. Malleable iron is cast as white iron
and then heat-treated to impart ductility to an
otherwise brittle material. Malleable iron possesses
considerable ductility and toughness due to the
nodular graphite and a lower carbon metallic
matrix. It has good fatigue strength and damping
capacity, good corrosion resistance, good magnetic
permeability, and low magnetic retention for
magnetic clutches and brakes. Malleable iron, like
medium-carbon steel, can be heat treated to obtain
different matrix microstructures (ferrite, pearlite,
tempered pearlite, bainite, tempered martensite, or
a combination of these) and mechanical properties.
Malleable and gray irons differ in two respects: the
iron carbide is partially or completely dissociated
in malleable cast iron; the dissociation occurs only
when the alloy is solid. However, the dissociation in
gray cast iron occurs during the early stages of
solidification; hence the difference in the character
of graphite in each material.
Figure 4: Coarse pearlite in annealed malleable iron
Machinability – Malleable Cast Irons
The machinability of malleable iron is considered to
be better than that of free-cutting steel. Use lowstrength 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. Austempered
ductile 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
35
Metallurgy and Machinability
treatment. The microstructure consists of
spheroidal graphite in a matrix of acicular ferrite
and stabilized austenite (called ausferrite) (Figure
5). The fine-grained acicular ferrite provides an
exceptional combination of high tensile strength with
good ductility and toughness. ADI can be given a
range of properties through control of austempering
conditions. Compared to conventional grades of
ductile iron, ADI offers twice the tensile strength for
a given level of elongation.
Compacted graphite iron (CGI) (ASTM A842)
has a microstructure in which the graphite is
interconnected like the flake graphite in gray cast
iron, but the graphite in CGI is coarser and more
rounded (Figure 6). In other words, the structure of
CGI is between that of gray and ductile iron. The
graphite morphology allows better use of the
matrix, yielding higher strength and ductility than
gray irons. The interconnected graphite in CGI
provides better thermal conductivity and damping
capacity than the spheroidal graphite in ductile
iron. Although the CGI is less section-sensitive
than gray iron, high cooling rates are avoided
because of the high propensity of the CGI for
chilling and high nodule count in thin sections.
Figure 5: Austempered ductile iron
Machinability – Austempered Ductile Irons
The machinability of the softer grades of
austempered ductile iron (ADI) is equal or superior
to that of steels with equivalent strength. ADI can be
machined complete in the soft, as-cast state before
heat treatment. This enables faster machine feeds
and 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. Processing
sequence for parts processed to the
higher strength:
• cast the component
Figure 6: Compacted graphite
Machinability – Compacted Graphite Iron
The graphite morphology in compacted graphite
iron enables chipbreaking but is strong enough to
prevent powdery chip formations. This combination
is ideal for good machinability. As a result, the
machinability of compacted graphite iron lies
between that of gray iron and ductile iron for a
given matrix structure. Use low-strength ductile iron
machining recommendations.
• 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 recommendations
during machining.
36
Photomicrographs courtesy of Buehler Ltd., Lake
Bluff, Illinois, USA, www.buehler.com
Metallurgy and Machinability
Gray Cast Irons & Gray, Austenitic
standard
materials
Gray Cast Irons
Gray, Austenitic
UNS
tensile strength
hardness
HB
ASTM
48
ASTM
A126
ASTM
A159 &
SAE J431
ASTM
A278 &
ASME
AS278
ASTM
A319
ASTM
A436
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)
—
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
F11401
138 MPa (20 ksi) min.
156
F11501
145 MPa (21 ksi) min.
156
F11701
172 MPa (25 ksi) min.
174
25 (A-C)
F12101
207 MPa (30 ksi) min.
210
30 (A-C)
F12102
214 MPa (31 ksi) min.
210
F12401
241 MPa (35 ksi) min.
212
35 (A-C)
F12801
276 MPa (40 ksi) min.
235
40 (A-C)
F12802
283 MPa (41 ksi) min.
235
F12803
276 MPa (40 ksi) min.
235
F13101
310 MPa (45 ksi) min.
250
F13102
310 MPa (45 ksi) min.
250
F13501
345 MPa (50 ksi) min.
265
F13502
345 MPa (50 ksi) min.
265
F13801
379 MPa (55 ksi) min.
282
F13802
379 MPa (55 ksi) min.
282
F14101
414 MPa (60 ksi) min.
302
F14102
414 MPa (60 ksi) min.
302
60
F14801
483 MPa (70 ksi) min.
—
70
F15501
552 MPa (80 ksi) min.
—
80
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
Class lll
G4000
20 (A-C)
20
Class A
25
30
Class B
35
Class C
40
45 (A-C)
45
50 (A-C)
50
55 (A-C)
55
60 (A-C)
Grade, Type or Number
37
Metallurgy and Machinability
Malleable Cast Irons & Pearlitic, Martensitic
standard
materials
Malleable
Cast Irons
UNS
tensile strength
yield strength
hardness
HB
ASTM
A47
ASTM
A220
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
F20003
516.5 MPa (75 ksi) min.
379.3 MPa (55 ksi) min.
187-241
M5503
F20004
620.3 MPa (90 ksi) min.
482.2 MPa (70 ksi) min.
229-269
M7002
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
ASTM
A602 &
SAE J158
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
F24130
483 MPa (70 ksi) min.
345 MPa (50 ksi) min.
196-241
60004
F24830
586 MPa (80 ksi) min.
483 MPa (70 ksi) min.
217-269
70003
F25530
655 MPa (95 ksi) min.
552 MPa (80 ksi) min.
241-285
80002
F26230
724 MPa (105 ksi) min.
621 MPa (90 ksi) min.
269-321
90001
Grade, Type, or Number
Ductile Cast Iron & Ductile, Austenitic
standard
materials
Ductile Cast Iron
Ductile, Austenitic
38
UNS
tensile strength
yield strength
hardness
HB
ASTM
A395
A476
A536
ASTM
A439
ASTM
A571
AMS
as req’d
SAE
J434
F30000
as required
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
D4512
F33101
414 MPa (60 ksi) min.
310 MPa (45 ksi) min.
190
F33800
552 MPa (80 ksi) min.
379 MPa (55 ksi) min.
187-255
80-55-06
163
80-60-03
MIL-I24137
DQ & T
65-45-12
5315
(A)
D5506
F34100
552 MPa (80 ksi) min.
414 MPa (60 ksi) min.
F34800
689 MPa (100 ksi) min.
483 MPa (70 ksi) min.
241-302 100-70-03
5316
F36200
827 MPa (120 ksi) min.
621 MPa (90 ksi) min.
270-350 120-90-02
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
F43005
414 MPa (60 ksi) min.
207 MPa (30 ksi) min.
202-273
D-4
F43006
379 MPa (55 ksi) min.
207 MPa (30 ksi) min.
131-185
D-5
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
F43020
379 MPa (50 ksi) min.
207 MPa (30 ksi) min.
—
(B)
F43021
345 MPa (50 ksi) min.
172 MPa (25 ksi) min.
—
(C)
D7003
D-2M-1, D-2M-2
Grade, Type, or Number
Metallurgy and Machinability
Austempered Ductile Iron (ADI)
standard
materials
UNS
tensile strength
yield strength
hardness
HB
ASTM
A897-90
Austempered
n/a
850 MPa (125 ksi) min.
550 MPa (80 ksi) min./elongation 10%
269-321
Ductile Iron (ADI)
n/a
1050 MPa (150 ksi) min.
700 MPa (100 ksi) min./elongation 7%
302-363
125-80-10
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
Grade, Type, or
Number
Compacted Graphite Iron (CGI)
standard
materials
UNS
tensile strength
yield strength
hardness
HB
ASTM
A842
Compacted
n/a
250 MPa min.
175 MPa min./elongation 3%
179 Max.
Graphite Iron (CGI)
n/a
300 MPa min.
210 MPa min./elongation 1.5%
143-207
250
300
n/a
350 MPa min.
245 MPa min./elongation 1.0%
163-229
350
n/a
400 MPa min.
280 MPa min./elongation 1.0%
197-255
400
n/a
450 MPa min.
315 MPa min./elongation 1.0%
207-269
450
Grade, Type, or
Number
Nickel (Ni) Hard / White Cast Iron
standard
materials
UNS
properties
hardness
HB
ASTM
A532 (class)
Austempered
F45000
nickel-chromium irons
550-600
Ductile Iron (ADI)
F45001
nickel-chromium irons
550-600
(I) A, Ni hard
(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
Grade, Type, or
Number
39
Metallurgy and Machinability
Cast Iron Cross-Reference / Workpiece Comparison Table
UNS
USA
Australia
Belgium
Denmark
France
T150
FGG10
FGG15
GG10
GG15
T220
FGG20
GG20
FGL150
FGL150A
FGL200A
FGL250A
FGL200
FGG25
GG25
FGL250
FGL300A
FGG30
GG30
FGG35
GG35
FGL300
FGL350A
FGL400A
FGL350
FGG40
GG40
Gray Cast Iron
ASTM 48, ASME SA278, ASTM A159, SAE J431
F10004
G1800
F10005
G2500
F10006
F10007
F10008
F11401
F11701
F12101
F12401
G3000
G3500
G4000
20-A
20
25-A
25
30-A
30
35-A
35
F12801
F13101
40-A
45-A
45
F13501
50-A
50
55-A
50
60-A
60
F13801
F14101
FGL400
Gray, Austenitic
ASTM A436
F41000
F41001
F41002
1
1b
2
F41003
F41004
2b
3
F41005
4
F41006
5
F41007
Malleable Iron
ASTM 602, SAE J158, ASTM A7
F20000
F22200
F22400
40
6
M3210
M4504
M5003
M5503
M7002
M8501
32510
35018
L-NiCuCr1562
L-NiCuCr1563
L-NiCr202
S-NiCr202
L-NUC1562
L-NUC1563
L-NC202
L-NC203
L-NiCr303
S-NiCr303
NiSiCr3055
L-Ni35
S-NiCr353
L-NSC2053
L-NSC3055
L-N35
Metallurgy and Machinability
Germany
Great Britain
International
Italy
Japan
Sweden
Gray Cast Iron
ASTM 48, ASME SA278, ASTM A159, SAE J431
Ch130
Ch170
GG-10
Ch190
Ch210
Ch230
G10
100
150
GG-15
100
150
180
FC10-1
FC15-2
GG-20
200
200
G20
FC20-3
220
250
260
250
G25
FC250-4
GG-25
GG-30
300
300
G30
FC25-4
FC30-5
GG-35
350
350
G35
FC350-6
0212-00
0215-00
0217-00
0219-00
0221-00
0223-00
0110-00
G15
0125-00
400
Gray, Austenitic
ASTM A436
GGL-NiCuCr1562
GGL-NiCuCr1563
GGL-NiCr202
GGL-NiCr203
GGL-NiCr303
F1
F1
F2
L-NiCr202
F2
F3
GGL-NiSiCr3055
L-NiCuCr1562
L-NiCuCr1563
L-NiCr202
0523-00
L-NiCr203
L-NiCr303
L-NiSiCr2053
L-NiSiCr3055
L-Ni35
S2
Malleable Iron
ASTM 602, SAE J158, ASTM A7
41
Metallurgy and Machinability
Cast Iron Cross-Reference / Workpiece Comparison Table
UNS
USA
Australia
Belgium
370-17
FNG38-17
Denmark
France
Ductile Cast Iron
ASTM A395, ASTM A476, ASTM A536, SAE J434
F32800
60-40-18
D4018
715
FGS350-22
716
FGS350-22L
FGS400-15
FGS400-18
FGS400-18L
F33100
65-45-12
400-12
FNG42-12
500-7
FNG50-7
D4512
F33101
5315
F33800
80-55-06
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
F43000
D-2
S-NC202
F43001
D-2B
Ductile Cast Iron, Austenitic
ASTM A439
L-NiCr203
S-NC203
S-NiCr203
F43002
D-2C
F43003
D-3
S-Ni22
S-N22
F43004
D-3A
S-NiCr301
S-NC301
F43005
D-4
S-NiSiCr3055
S-NSC3055
F43006
D-5
S-Ni35
F43007
D-5B
F43010
D-2M-1
S-NC303
S-N35
S-NC353
D-5S
D-2M-2
42
S-NM234
Metallurgy and Machinability
Germany
Great Britain
International
Italy
GS370-17
Japan
Sweden
Ductile Cast Iron
ASTM A395, ASTM A476, ASTM A536, SAE J434
GGG-40
350/22
350-22
350/22L40
350-22L
400/18
400-15
0717-02
400-18
0717-15
400/18L20
FCD37-0
FCD40-1
0717-00
400-18L
GGG-50
GGG-60
GS400-12
500/7
500-7
GS500-7
FDC45-2
FCD50-3
0727-02
FCD60-4
GGG-70
GGG-80
700/2
700-2
GS700-2
FCD70-5
800/2
800-2
GS800-2
FCD80-6
900/2
900-2
S2
S-NiCr202
Ductile Cast Iron, Austenitic
ASTM A439
GGG-NiCr202
S2W
GGG-NiCr203
S2B
S-NiCr203
GGG-Ni22
S2C
S-Ni22
GGG-NiCr303
S3
S-NiCr303
GGG-NiCr301
S3
GGG-NiSiCr3055
S-NiCr301
S-NiSiCr3055
GGG-Ni35
S-Ni35
GGG-NiCr353
S-NiCr353
GGG-NiMn234
S2M
S-NiMn234
43
Expert Application Advisor – Cast Irons
Gray Cast Iron and Austenitic, Gray Iron (120-320 HB)
ASTM: A48I: class 20, 25, 30, 35, 40, 45, 50, 55, 60
ASTM: 126: class A, B, C
ASTM: A159 & SAE: J431; G1800, G2500, G3000, G3500, G4000
ASTM: A436; 1, 1b, 2, 2b, 3, 4, 5, 6
Material Characteristics
workpiece breakout
•
out-of-balance condition may exist
•
chucking on cast surface can be difficult
1. Use PVD-coated grade KC5010 at
moderate to low speeds.
•
tendency to break out during exit from cut
2. Reduce feed rate during exit.
•
contains abrasive elements; sand may be
embedded in the cast surface
3. Pre-chamfer casting edge at exit.
•
potential for chatter on thin wall sections
workpiece chatter
•
corners and thin sections can be chilled
(hard and brittle)
1. Use a smaller nose radius.
•
potential scale, inclusions
4. Increase toolholder lead angle.
2. Apply insert geometries that are free-cutting,
such as MG-FN and MG-RP.
3. Increase feed to stabilize workpiece.
Common Tool Application Considerations
Problems & Solutions
4. Shorten toolholder or bar overhang.
excessive edge wear
5. Check toolholder and workholding
system for rigidity.
1. Use grade KC9315 or KT315 if running at
moderate to high speeds.
6. Use Top Notch Turning (GX-T style) insert for
increased tooling rigidity.
2.. Use silicon nitride-based ceramic grades Kyon
3500 or Kyon 1310, or PCBN grades, if running
at ultra-high speeds. Machining system must
have the rigidity and horsepower required to
run 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 geometries
such as MA, GX-T or GA-T.
5. Use inserts with an MT-land edge prep.
44
Expert Application Advisor – Cast Irons
Ductile Iron (120-320 HB)
ASTM: A395, A476, A536; 60-40-18, 65-45-12, 80-55-06, 80-60-03, 100-70-03, 120-90-02
SAE: J434; DQ & T, D4018, D4512, D5506, D7003
AMS: 5315, 5316
ASTM: 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
•
machining difficulties may develop from flank
and crater wear on the tool
•
hard spots are common concentrations of
carbide in the structure
•
higher tensile strength requires good rigidity
in machining system
•
workpiece material structure may
vary dramatically
•
decreased tool life should be expected,
compared to machining gray or malleable
cast iron
Malleable Cast Iron (120-320 HB)
ASTM: A47: 32510, 35018
ASTM: A602 & SAE J158; M3210, M4504, M5003, M5503, M7002, M8501
ASTM: 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
Common Tool Application Considerations
Problems & Solutions
excessive edge wear
1. Apply grade KC9315 to achieve higher speeds
and longer tool life.
2. Use grade KC9325 for general purpose and
interrupted cutting.
3. Apply grade KC9315 or KT315 if edge wear is
excessive in smooth cuts.
4. Use ceramic grade Kyon 3400. Increase speed
and make sure the machining set up and workpart clamping is rigid.
5. Increase feed to reduce time in cut.
crater wear
•
generally easy to machine at
aggressive conditions.
chipping
1. Use a strong negative-rake insert geometry.
Apply the MX-T, GA-T, or MA insert geometry
as a first choice; use MG-UN insert geometry
as a second choice.
2. Select a T-land or large hone edge prep for
greater edge strength.
3. Increase toolholder lead angle.
4. Reduce toolholder or boring bar overhang.
5. Ensure proper insert seating.
6. Apply grade KC9325.
7. Use grade KC9325, increase speed, and
decrease feed when cutting with interruptions.
1. Apply grade KC9315 or KT315.
8. Choose grade Kyon 3500 to replace Kyon 3400
for heavy interruptions.
2. Reduce speed to lower the heat at cutting edge.
catastrophic failure
3. Apply ceramic grade Kyon 3400 when
machining at high speeds.
1. Reduce speed and feed.
4. Apply large amounts of flood coolant.
torn or dull workpiece
2. Use a T-land plus hone edge prep.
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.
45
Expert Application Advisor – Cast Irons
Austempered Ductile Iron (269-444 HB)
ASTM: A897; 125-80-10, 150-100-7, 175-125-4, 200-155-1, and 230-185
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 to
high-strength ductile irons. Due to the higher
strength of these materials, tool life is shortened
compared to conventional irons. Use high-strength
ductile iron (>80 ksi) machining recommendations
for these materials. See KENNA PERFECT
recommendations on pages 6-13.
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 to
lower-strength ductile irons.
Kennametal Tooling System Solutions
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!
46
Failure Mechanism Analysis
Edge Wear*
Corrective Action
• Increase feed rate.
• Reduce speed (sfm).
Chipping
• Use more wear
resistant grade.
• Apply coated grade.
• Reduce depth-of-cut
(doc).
• Use grade with higher
hot hardness.
Thermal Cracking
Corrective Action
• Properly apply
coolant.
• Reduce speed.
Corrective Action
• Change lead angle.
• Consider edge
preparation.
• Apply different
grade.
• Adjust feed.
Built-Up Edge
• Reduce feed.
• Apply coated grades.
Crater
Corrective Action
• Reduce feed rate.
• Reduce speed (sfm).
• Check rigidity of
system.
• Increase lead angle.
Depth-of-Cut Notching
Heat Deformation
Corrective Action
• Reduce speed.
• Reduce feed.
Corrective Action
• Utilize stronger grade.
• Consider edge
preparation.
Corrective Action
• Increase speed
(sfm).
• Increase feed rate.
• Apply coated
grades or cermets.
• Utilize coolant.
• Edge prep
(smaller hone).
Catastrophic Breakage
• Apply coated grades
or cermets.
• Utilize coolant.
Corrective Action
• Utilize stronger
insert geometry
grade.
• Reduce feed rate.
• Reduce depth-ofcut (doc).
• Check rigidity of
system.
*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.
47
Machinability Data – Cast Iron
Gray Cast Iron
Ductile Cast Iron
The ideal turning insert geometry for machining
gray cast iron should have the following
characteristics:
The ideal turning insert geometry for machining
ductile cast iron should have the following
characteristics:
•
square or diamond shaped for
maximum strength
•
square or diamond shaped for
maximum strength
•
negative insert geometry for maximum
strength and number of cutting edges
•
negative insert geometry for maximum strength
and number of cutting edges
•
minimum or no positive-rake chip-forming
insert geometry for maximum edge strength
•
positive-rake chip-forming insert geometry for
freer cutting action and chip control
•
medium edge hone on carbide inserts
and a T-land edge prep on ceramic/sialon-grade
inserts
•
light edge hone on carbide inserts and a T-land
edge prep on ceramic/sialon-grade inserts
Pre-chamfer workpiece whenever possible to avoid
workpiece material breakout and interrupted cut
shock damage to insert edge.
48
Insert Edge Preparation
Edge Preparation for Kennametal’s Advanced Cutting Tool Materials
Edge preparation is the term for the intentional
modification of the cutting edge of an indexable
insert 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 but
lower 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 to
edge 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 for
standard inserts made with specific ceramic grades
are determined by target applications and listed in
the KENNA PERFECT insert selection system.
There is a tradeoff to the benefits of this edge
preparation. Increasing the width “T” of the T-land or
the angle “A” increases the overall cutting forces
acting 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-land
width smaller than the feed rate. For heavily
interrupted turning, hard turning (workpiece >50
HRC), and milling applications, use a T-land width
larger 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 generally
are recommended for continuous or finishing
operations; however, depending on the workpiece
material, they can be used for interrupted or
heavy cutting.
There are three choices of edge preparation for
ceramic materials:
3. T-land plus hone
1. T-land
2. hone
3. T-land plus hone
In aggressive applications, such as interrupted
turning, chipping can occur at the intersection of
the T-land and flank surface of the ceramic insert.
This condition may be eliminated by applying a
small hone to the intersection while leaving the
other attributes of the T-land unchanged.
1. T-land
T lands protect the insert cutting edge by directing
forces into the greater part of the insert, rather
than to the smaller cross section of the sharp
edge, during the metalcutting process. This helps
prevent chipping and catastrophic failure.
49
Chip Control Geometries
Kenloc Inserts
operation
insert
style
application
wiper,
feed rate – inches
insert
geometry
profile
.0015 .0025 .004
.004 .006 .010
.006
.016
.010 .016 .025
.025 .040 .060
.060
.160
.100
.250
.200
.500
.008 - .016
(0,2 - 0,4)
MG-FW
.010 - .080
(0,3 - 2,0)
finishing
wiper,
medium
.040
.100
depth of cut – inches
.012 - .024
(0,3 - 0,6)
MG-MW
.030 - .200
(0,8 - 5,1)
machining
wiper,
MM-RW
roughing
(single sided)
finishing
MG-FN
medium
MG-UN
.010 - .050
(0,3 - 1,3)
.050 - .500
(1,3 - 12,7)
.005 - .012
(0,1 - 0,3)
.010 - .100
(0,3 - 2,5)
.008 - .020
(0,2 - 0,5)
.030 - .150
(0,8 - 3,8)
machining
roughing
MG-RP
roughing
MG-RN
heavy
MM-RM
roughing
(single sided)
.010 - .025
(0,3 - 0,6)
.045 - .250
(1,1 - 6,4)
.010 - .025
(0,3 - 0,6)
.045 - .250
(1,1 - 6,4)
heavy
MM-RH
roughing
(single sided)
.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 – (mm)
0,04 0,063 0,01
0,1
0,16
0,25
0,16
0,4
0,25
0,4
0,63
1,0
1,6
2,5
5,0
0,63
1,0
1,6
2,5
4,0
6,3
10,0
depth of cut – (mm)
50
Chip Control Geometries
Screw-On Inserts
operation
insert
style/
application
wiper,
feed rate – inches
insert
geometry
profile
.0015 .0025 .004
.006
.010 .016
.025
.040
.060
.100
.200
.004
.016
.025 .040
.060
.100
.160
.250
.500
.006
.010
depth of cut – inches
.003 - .013
(0,1 - 0,3)
MT-FW
.008 - .060
(0,2 - 1,5)
finishing
wiper,
medium
.005 - .020
(0,1 - 0,5)
MT-MW
.016 - .130
(0,4 - 3,3)
machining
fine
.003 - .010
(0,1 - 0,3)
MT-11
finishing
fine
.008 - .050
(0,2 - 1,3)
.002 - .010
(0,1 - 0,3)
MT-UF
.005 - .050
(0,1 - 1,3)
finishing
finishing
MT-LF
medium
MT-MF
.007 - .015
(0,2 - 0,4)
.030 - .090
(0,8 - 2,3)
.009 - .017
0,2 - 0,4
.045 - .090
1,1 - 2,3
machining
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
0,4
0,63
1,0
1,6
2,5
4,0
6,3
10,0
0,16
0,25
depth of cut – (mm)
51
Kennametal Grade System for Cutting Materials
Cermet – (CERamics with METallic binders)
grade
coating
KT315
composition and application
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 steels
and stainless steels. Performs very well in cast and ductile iron applications too. Provides long and
consistent tool life and will produce excellent workpiece finishes.
C class ISO class
C3
C7
K10 - K20
M10 - M20
P10 - P20
PVD Coated Carbide Grades
grade
coating
KC5010
composition and application
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.
C class ISO class
C3
C4
K10 - K20
M10 - M20
P10 - P20
CVD Coated Carbide Grades
grade
coating
KC9315
composition and application
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 size
consistency 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.
KC9325
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.
C class ISO class
C3 - C4 K10 - K25
C2 - C3 K15 - K30
Silicon Nitride-Based Ceramic
grade
coating
KY1310*
composition and application
composition: An advanced sialon ceramic grade.
application: Grade KY1310 provides maximum wear resistance. Use it for
high-speed continuous turning of gray cast iron, including through scale.
C class ISO class
–
K05-K15
C3
K10 - K30
C2
K15 - K35
M15 - M30
*KY1310 will be available January 2004.
KY3400
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
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
grade
KB9640
52
coating
composition and application
composition: A high CBN content, solid PCBN structure having multiple cutting edges and a CVD
alumina coating.
application: The KB9640 grade is applied in the roughing to semi-finishing of fully pearlitic gray
cast iron, chilled irons, high chrome alloy steels, sintered powdered metals, and heavy cuts in hardened steels (>45 HRC). Use for finished chilled cast iron and fully pearlitic cast iron. Do not apply on
finishing hardened steels. KB9640 can be applied effectively when roughing hardened steels.
C class ISO class
C1
K05-K15
Kennametal Grade System for Cutting Materials
Gray Cast Irons
Ceramic Cutting Tools
Ductile Cast Irons
Ceramic Cutting Tools
KY3500“
Carbide Cutting Tools
Carbide Cutting Tools
53
KENNAMETAL
TOOL MANAGEMENT SOLUTIONS
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.
ToolBoss™™ System
Our unique, new, easy-to-use/
easy-to-audit tool dispenser
can help reduce your:
■
tool-buying costs by as much as 90%!
■
tool-inventory costs by up to 50%!
■
tool-supply costs by nearly 30%!
www.kennametal.com
54
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
....................
Insert Identification System . . . . . . . . . . . . . . . . . . . . . . . .
63
66
55
Three Ways To
Improve Your
Turning Operations!
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 Productivity
Kennametal’s new wiper geometries allow you to double your
current feed rate and still achieve surface finishes comparable
to conventional inserts. You’ll also see equivalent or better tool
life using the appropriate KENNA PERFECT grade specifically
designed for your workpiece material.
Better Workpiece Finish
These 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.
Kennametal Wiper
Technology –MW
Conventional
Turning Insert
doc ............0.050
feed ..........0.012 ipr
speed ........1,100 sfm
finish ........160 Ra (µin.)
56
doc ................0.050
feed ................0.020 ipr
speed..............1,100 sfm
finish ..............60 Ra (µ in.)
Negative Wiper Inserts – Application Technology
Surface Finish
Theoretical Surface Finish – Ra
µin. (µm)
insert
feed rate – ipr (mm/rev)
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)
3/8 IC
14 30 50 80
(0,3) (0,75) (1,3) (2)
1/2 IC
—
3/4 + 1 IC
—
—
—
23 41 63 91 120 160 200 250
—
(0,6) (1) (1,6) (2,2) (3) (4) (5) (6,2)
—
—
—
—
—
—
—
—
—
103 141 184 232 287 347 413
(2,6) (3,5) (4,6) (5,8) (7,2) (8,7) (10,3)
How It Works
Wiper Insert
Standard Insert
LEGEND
f – feed
r – corner radius
rw – wiper radius
Ra – surface finish
Corner Radius Configuration
CNMG and WNMG wiper
inserts create a true corner
radius on the workpiece, just
as a standard insert does.
DNMG and TNMG wiper inserts do
not provide an exact corner radius on
the workpiece. The radius produced
falls within a ±.0025 tolerance band.
(blue lines)
57
Negative Wiper Inserts – Application Technology
C– and W–Style Inserts
Kenloc® Toolholders
surface with wiper effect
surface with standard insert edge
D– and T–Style Inserts
CN . . 80° corner
insert requires MCLN
5° reverse lead
angle toolholder
CN . . 100° corner
insert requires MCRN
15° lead angle toolholder
CN . . 100° corner
insert requires MCKN
15° lead angle toolholder
WN . . 80° corner insert
requires MWLN 5° reverse
lead angle toolholder
Kenloc Toolholders
surface finish with wiper effect
surface with designated insert nose radius
surface finish with .016 radius
DN . . 55° corner insert
TN . . 60° corner insert
requires MDJN 3° reverse
requires MTJN 3° reverse
lead angle toolholder
lead angle toolholder
Kenloc Toolholders
S–Style Inserts
surface with wiper effect
surface with standard insert edge
SN . . 90° corner insert
SN . . 90° corner insert
requires MSRN 15° lead
requires MSKN 15° lead
angle toolholder
angle toolholder
NOTE: The holder guidelines above also apply to ceramic/PCBN wiper inserts in similar insert shapes; i.e.: CNGA, CNGX, DNGA, etc.
58
Positive Wiper Inserts – Application Technology
Positive geometry wiper inserts offer the same
advantages as negative style inserts. When
compared to conventional inserts, feed rates
can be doubled while maintaining surface
finish, or surface finish can be improved by a
multiple of 2.5 while maintaining productive
feed rates.
-FW
-MW
Finishing Wiper
Medium
Machining Wiper
Surface Finish
Theoretical Surface Finish – Ra
µin. (µm)
CCMT and CPMT Inserts
insert
feed rate – ipr (mm/rev)
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)
1/4 IC
1
6
14
22
35
49
(0,03) (0,15) (0,35) (0,55) (0,90) (1,25)
—
—
—
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)
—
Screw-On Toolholders and Boring Bars
surface with wiper effect
surface with designated insert
nose radius
C.MT 80° inserts require 5° reverse lead
SCL toolholders.
C.MT 100° inserts
require 15° lead
SCK toolholders.
SDN
SDJ
DCMT– and DPMT–Style Inserts
surface finish with wiper effect
surface with designated insert nose radius
surface finish with .016 radius
SDU
D.MT 55° inserts require a 3° reverse lead angle and can be
used in SDN, SDU, and SDJ style toolholders and boring bars.
59
Application Guidelines – Cast Iron
Conversion Charts
hardness
Brinell
HB
654
634
615
595
577
560
543
525
512
496
481
469
455
443
432
421
409
400
390
381
371
362
353
344
336
327
319
311
301
294
286
279
271
264
258
inch to metric
Rockwell
HRB
HRC
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
109.0
108.5
108.0
107.5
107.0
106.0
105.5
104.5
104.0
103.0
102.5
60
59
58
57
56
55
54
53
52
51
50
49
48
47
46
45
44
43
42
41
40
39
38
37
36
35
34
33
32
31
30
29
28
27
26
Brinell
HB
253
247
243
237
231
228
222
216
210
205
200
195
190
185
180
176
172
169
165
162
159
156
153
150
147
144
141
139
137
135
132
130
127
125
123
Rockwell
HRB
HRC
101.5
101.0
100.0
99.0
98.5
98.0
97.0
96.0
95.0
94.0
93.0
92.0
91.0
90.0
89.0
88.0
87.0
86.0
85.0
84.0
83.0
82.0
81.0
80.0
79.0
78.0
77.0
76.0
75.0
74.0
73.0
72.0
71.0
70.0
69.0
25
24
23
22
21
20
18.6
17.2
15.7
14.3
13
11.7
10.4
9.2
8
6.9
5.8
4.7
3.6
2.5
1.4
.30
—
—
—
—
—
—
—
—
—
—
—
—
—
diameter Ø
inches
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
25,0
1.000
25,4
1.260
32,0
1.500
38,1
1.968
50,0
2.000
50,8
2.480
63,0
2.500
63,5
Turning Formulas
to find
inches
.010
.015
.030
.050
.100
.125
.150
.250
.375
.500
feed
60
ipr
mm/rev
.003
.005
.005
.006
.007
.008
.009
.010
.011
.012
.076
.120
.127
.152
.178
.203
.229
.254
.279
.305
sfm
300
400
500
600
800
1000
1200
2000
4000
10000
rpm
mpm
sfm ÷ 3.27
sfm
mpm x 3.27
ipr
ipm
rpm
ipm
ipr x rpm
mm
inch x 25.4
inches
mm ÷ 25.4
cut
time
loc
ipr x sfm (minutes)
Abbreviations
speed
mm
0,254
0,381
0,762
1,270
2,540
3,175
3,810
6,350
9,525
12,700
formula
d x rpm
3.82
sfm x 3.82
d
sfm
NOTE: Values in shaded areas are beyond normal range and
given for information only.
doc
diameter Ø
inches
mm
3.000
76,2
3.150
80,0
3.500
88,9
3.937
100,0
4.000
101,6
4.921
125,0
5.000
127,0
6.000
152,4
6.299
160,0
7.000
177,8
7.874
200,0
8.000
203,2
9.842
250,0
10.000
254,0
12.000
304,8
12.401
315,0
14.000
355,6
15.748
400,0
m/min.
91
122
152
183
244
305
366
610
1219
3048
surface finish (Ra)
µ inch
µm
492
12,5
248
6,3
126
3,2
63
1,6
31
0,8
16
0,4
sfm =
surface feet per minute
rpm =
mpm =
revolutions per minute
meters per minute
ipr =
ipm =
inches per revolution
inches per minute
d
diameter
=
mm =
millimeters
loc
length of cut
=
Application Guidelines – Cast Iron
Nose Radius Selection and Surface Finish for Conventional Inserts*
1
2
3
4
Nose radius and feed rate have the greatest impact
on surface finish. To determine the nose radius
required for a theoretical surface finish, use the
following procedure and the chart above.
1
Locate the required surface finish (rms or AA)
on the vertical axis.
2
Follow the horizontal line corresponding to the
desired theoretical finish to where it
intersects the diagonal line corresponding
to the intended feed rate.
3
Project a line downward to the nose radius
scale and read the required nose radius.
4
If this line falls between two values, choose
the larger value.
NOTE: Peaks produced with a small radii insert (top) compared
to those produced with a large radius insert (bottom).
• If no available nose radius will produce the
required 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.
61
Insert Size Selection Guide
Cast Iron Geometries
maximum depth of cut
insert shape
IC
cutting
edge
length
finishing
MG-FN
MG-FW
MA-T0820
T0420-FW
.250
.375
.500
.625
.750
1.000
.250
.375
.500
.625
.250
.375
.500
.625
.750
1.000
.275
.433
.590
.748
R-Round
.375
.500
.625
.750
1.000
.188
.250
.313
.375
.500
S-Square
.375
.500
.625
.750
1.000
.375
.500
.625
.750
1.000
..075
..120
T-Triangle
.250
.375
.500
.625
.433
.630
.866
1.060
.030
.060
.100
V-35° Diamond
.375
.500
.630
.866
W-Trigon
.250
.375
.500
.157
.236
.315
C-80° Diamond
D-55° Diamond
62
.050
.075
.120
general purpose
MG-UN
MG-RP
MG-MW
roughing
MX-T0820
..MA
– S0820
.150
.250
.313
.375
.500
.250
.313
.375
.500
.125
.175
.150
.200
.112
.200
.250
.300
.400
.112
.200
.250
.300
.400
.150
.250
.313
.375
.500
.150
.250
.313
.375
.500
.125
.175
.250
.150
.200
.300
.045
.060
.070
.120
.075
.100
.100
.150
.120
.200
.030
.060
.100
Turning Tool Performance Report
COMPANY & LOCATION
DATE
ENGINEER
CUSTOMER NAME
MATERIAL TYPE AND CONDITION
PART DESCRIPTION
CUTTING CONDITION (CIRCLE)
HARDNESS
MACHINE & TYPE
OPERATION
CONDITION OF MACHINE
HP
CONSTANT SFM
■ YES
■ NO
PART CONFIGURATION
COMMENTS
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
PERFORMANCE, TECHNICAL & COST DATA
OPERATION NUMBER
TURRET POSITION
TOOLHOLDER
INSERT STYLE
GRADE
DEPTH OF CUT
LENGTH OF CUT
FEED RATE (IPR)
WORKPIECE DIAMETER
CUTTING SPEED
TEST 1
TEST 2
TEST 3
RPM
SFM
CUTTING TIME PER PIECE (MINUTES) (30 SECONDS = .5)
PIECES PER EDGE
CUTTING TIME PER EDGE (MINUTES) (11 x 12)
CUTTING EDGES PER INSERT
PIECES PER INSERT (14 x 12)
REASONS FOR INDEXING
TYPE OF COOLANT
HORSEPOWER REQUIRED
FINISH (RMS)
CHIP CONTROL (GOOD, FAIR, POOR)
INSERT COST
INSERT COST PER PIECE (21 ÷ 15)
MACHINE COST PER HOUR
MACHINE COST PER PIECE (11 x 23 ÷60)
TOTAL COST PER PIECE (24 + 22)
ESTIMATED ANNUAL PRODUCTION – PIECES
ESTIMATED ANNUAL COST (26 x 25)
ESTIMATED ANNUAL SAVINGS
63
KENNA PERFECT
Inserts
Steel
Stainless Steel
Cast Iron
Non-Ferrous Metals
High-Temperature Alloys
Hardened Materials
64
Table of
Contents
page
Insert Identification System . . . . . . . . . . . .
66
Kenloc® Negative Inserts . . . . . . . . . . . . . . . .
68
Screw-On Inserts . . . . . . . . . . . . . . . . . . . . . . .
81
Top Notch® Turning Inserts . . . . . . . . . . . . . . . . .
91
Kendex® Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . .
94
65