Roughing Ductile Iron
Tooling
| Romay | NTK | ||
| Cost per Tool: | $6.72 | $8.13 | |
| Tool: | CNMA 433 T7 CC-513 | CNGA 433 T00820 SX8 | |
| Parts per Edge: | 70 | 35 |
Cutting Conditions
| Cutting Speed: | 1600 SFM | 1600 SFM | |
| Feed: | 0.014″ IPR | 0.014″ IPR | |
| Depth of Cut: | 0.150″ DOC per side | 0.150″ DOC per side |
Results
| Annual Labor Savings: | $21,300.00 | ||
| Annual Hard Cost Savings: | $20,320.00 | ||
Distributor Salesmen Report (names removed)
Distributor has history dating back to 2001 showing customer has used the NTK CNGA 433 GRADE SX8. It is used as a rough turn in the fabrication of hydraulic pump bodies. The insert was changed every 30-35 parts, this depending on the size of the block. The 30-35 pieces was a number decided upon by the customer’s engineers to keep the lathe running. 30-35 parts kept the customer in the realm of other tool changes, thus most inserts were changed at the same time.
This is the insert in the Lathe that was changed the most. The NTK insert could reach maybe 50 pieces, however customer thought that would generate less production, with the machine being shut down more often. We did test the NTK SX1 grade as well. We still were nowhere close to a 60 or 70 part tool change.
Testing of a competitor’s insert had to double tool life to stay within the realm of other tool changes. It took a couple different grades and hones, but Romay was successful. We ended up with a CNMA 433 T7 CC-513 Romay insert. We are reaching the next plateau of tool changes and have had no issues of premature failure that I am aware of.
Facing Cast Iron
Tooling
| Romay | NTK | ||
| Toolholder: | DSJNR 1.64D | DSJNR 1.64D | |
| Insert: | SNMA 433 T7 | SNGA 434 T0820 | |
| Insert Grade: | CC-514 | KY3500 |
Cutting Conditions
| Cutting Speed: | 1125 SFM | 900 SFM | |
| Feed: | 0.012″ IPR | 0.009″ IPR | |
| Depth of Cut: | 0.070″ DOC | 0.070″ DOC |
Results
| Time Per Part: | 1:17 (minutes) | including down time | 1:37 (minutes) |
| Parts Per Edge: | 120 | 60 |
Cost Svaings
| Cost per Insert: | $7 | $12 | |
| Parts per Insert: | 960 | 480 | |
| Cost per Part: | $0.0073 | $0.0250 |
Roughing Cast Iron
| Operation: | Turning & Facing | ||
| Material: | Grey cast iron – heavy interruption | ||
| Hardness: | 200 Bhn | ||
| Speed: | 2200 SFPM | ||
| Feed: | .012″ IPR | ||
| Depth-of-cut: | .100″ DOC | ||
| Insert: | CNGA 434 T7 ROMAY CC-517 | CNGA 434 T7 Toshiba FX-105 | |
| 1st Edge: | 40 | 25 | |
| 2nd Edge: | 40 | 25 | |
| 3rd Edge: | 40 | 25 | |
| 4th Edge: | 40 | 25 | |
| Results: |
The Romay insert costs less and gave significantly better tool life. |
||
Roughing Cast Iron
| Operation: | Turning Pulley’s | ||
| Material: | 63000 Grey Cast Iron | ||
| Hardness: | 187-241 Bhn | ||
| Insert: | CNGA 432 T7 Romay CC-515 (SiN) | CNMA 432 Mitsubishi UC-505 (coated carbide) | |
| Roughing Speed: | 3500 SFPM | 1000 SFPM | |
| Roughing Feed: | .012″ IPR | .016″ IPR | |
| Roughing Depth-of-cut: | .180″ DOC | .180″ DOC | |
| Insert: | CNGA 432 T7 Romay CC-515 (SiN) | CNGA 432 T7 Kennametal Kyon 3500 (SiN) | |
| Finishing Speed: | 4000 SFPM | 2500 SFPM | |
| Finishing Feed: | .008″ IPR | .008″ IPR | |
| Finishing Depth-of-cut: | .035″ DOC | .035″ DOC | |
| 1st Edge: | 180 | 40 | |
| 2nd Edge: | 170 | 35 | |
| 3rd Edge | 185 | 42 | |
| 4th Edge: | 182 | 41 | |
| Results: |
Romay SiN significantly outperformed the Coated carbide in roughing and a competitors SiN in finishing, At a lower price. |
||
Rough turning gray cast iron
| Operation: | Rough Turning | ||
| Material: | Grey cast iron | ||
| Insert: | CNGA 433 T7 Romay CC-513 | CNGA 433 T Valenite Q65 | |
| Speed: | 1500 SFPM | 1500 SFPM | |
| Feed: | .018″ IPR | .018″ IPR | |
| Depth-of-cut: | .060″-.080″ | .060″-.080″ | |
| Tool Life: | 319pcs/edge | 289pcs/edge | |
| Results: |
Romay grade CC-513 increased tool life by 10% over Valenite’s Q65 at a |
||
Finishing Steel
| Operation: | O.D. Continuous Turning | ||
| Material: | 4140 Steel | ||
| Insert: | CNGA 432 T7 Romay CC-30 (black ceramic) | CNGA 432 Ceratip CER II | |
| Speed: | 450 SFPM | 450 SFPM | |
| Feed: | .005″ IPR | .005″ IPR | |
| Depth of cut: | .010″ | .010″ | |
| Length of cut: | 4.5″ | 4.5″ | |
| Results: |
Romay grade CC-30 black ceramic equaled Ceratip’s CER II, but at a much lower cost per insert. |
||
Hard-turning steel
| Operation: | Turning | ||
| Material: | S-7 die steel | ||
| Hardness: | HrC 58 | ||
| Speed: | 400 SFPM | ||
| Feed: | .003″ IPR | ||
| Depth-of-cut: | .010″ DOC | ||
| Insert: | CNGA 432 T2 CC-30-C Romay |
CNGA 432 T00625 A66N KYOCERA |
|
| Parts Per Edge: | 28 | 23 | |
| Reason for indexing: |
Flank wear – normal | Chipping – ! | |
| Results: |
Romay CC-30-C cost less and lasted longer than a competitors coated ceramic, Kyocera A66N. |
||
Finish Turn of 440-C Stainless Steel
|
Ceramic Inserts Eliminate Grinding |
|||
| Machine: | Mazak Slant Turn 30 NC lathe. | ||
| Part: | 440-C stainless steel, hardened to 52-56Rc | ||
| Rough-machined sleeve spacers made of 440-C stainless steel (hardened to 52-56 HRC) were being ground on both OD and ID to achieve a surface finish of 32 rms. The sleeves were 31/4″ in diameter and length, with walls .383″ thick. The grinding operation took 2.6hrs. per piece, floor to floor.When the finishing operation was moved to a Mazak Slant Turn 30 NC lathe tooled with CC-20 black ceramic inserts, size control was maintained, surface finish was improved, and there was significant savings in shop time. | |||
| Setup: | Grinding Data: | OD(turn) | ID(bore) |
| Insert: | CNG 434 | CNGA | |
| Grade: | CC-20 | CC-20 | |
| Workpiece Diameter: | 3.267″ | 2.5″ | |
| Depth of Cut: | .0075″ | .0055″ | |
| Feed Rate (IPR): | .003″ | .004″ | |
| Cutting Speed (SFM): | 400 | 400 | |
| Length of Cut/Pass (inches): | 2 ¼ | 3 ¼ | |
| Time in Cut/Pass (minutes): | 1:35 | 1:21 | |
| Pieces/Edge: | 10 | 10 | |
| Finish: | 32rms | 11-12rms | 11-12rms |
| Floor to Floor Time: | 2.6hrs. | 15:00 minutes total | |
|
Savings (Machining Time): |
90% |
||
Questions? Technical phone-support is available
517-769-6662
9am to 5pm – Eastern Standard Time, Monday through Friday