optimize productivity with advanced ceramic cutting tools · • advanced ceramic materials are now...

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Optimize Productivity with Advanced Ceramic Cutting Tools

Jan AnderssonGlobal Director, Tech Team and Marketing


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


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


Delivering the most productive cutting tool solutions possible for our customers with the absolute best customer service

we can provide.

Core Values


1945

1971

1973

1985

WG600

WG700

XSYTIN®‐1

A History of Continuous Innovation

1945

1971

1973

1985

WG‐600® XSYTIN®‐1

WG‐700™


The effectiveness of productive effort, as measured in terms of the rate of output per unit of input


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?


Metalcutting Physics

The four parameters of metalcutting:– Force– Stress– Thermal– Material


Forces


Forces

Axial

Radial

Tangential or Resultant

A + R ≈ T


Roughing


Medium to Finishing


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


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.


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.


Cutting Speed

(SFM

)

Carbide

WHISKER‐REINFORCED CERAMICSWG‐300®/WG‐600®/WG‐700™

Ceramic vs. Carbide Turning

PHASE‐TOUGHENED CERAMICSXSYTIN®‐1

Feed(IPT)


WG-300®

Whisker-Reinforced vs. Phase-Toughened

XSYTIN®-1


Comparable Strength

54,000 PSI 174,000 PSI100,000 PSI

WG‐300®WG‐600®WG‐700™ XSYTIN®‐1


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


Cutting Data and Tool LifeTool Life

Cutting Data

DOC

Fn

Vc

DOC

Fn

Vc


Typical Tool Wear

Flank Wear Notching

Ceramic Tool Wear

Crater Wear


Phase-Toughened vs. Traditional Ceramics

Whisker‐Reinforced SiAlON Phase‐Toughened

Speed

Feed


How can ceramics reduce cycle times and increase cost

savings?

Let’s view a few case studies…


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)


Stellite 6 Overlay Turning (60-62 R/C)

CompetitorCarbide ~ CNMM-544

Speed: 50 SFMFeed: .006”/rev

DOC: .028”


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)



From 6 hours to 6 minutes per part!!$110,700 per year cost savings!


GTD-111 Milling (40-42 R/C)

CompetitorSiAlON ~ RNGN-45

Speed: 2015 SFM

Feed: .002”/tooth

DOC: .100”


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


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)


P20 Milling (30-32 R/C)


• Today, only carbide• Some unsuccessful attempts to mill with ceramic

CGI Milling (compacted graphite iron)

Until now…


CGI Milling (compacted graphite iron)


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?

optimize productivity with advanced ceramic cutting tools · • advanced ceramic materials are now...

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