overcome the challenges of turning in stainless steels€¦ · stainless steel turning (iso-m...

1Copyright © 2019 Seco Tools AB

OVERCOME THE CHALLENGES OF TURNING IN STAINLESS STEELS

22 Copyright © 2019 Seco Tools AB

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SAFETY FIRST

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When machining in stainless steels, there are a number of common issues that limit efficiency:

▪ Poor chip control

▪ Poor surface finish

▪ Excessive notch wear on inserts

▪ Poor machinability

Typical Challenges in Stainless Steel Applications


Poor Chip Control

Poor chip control often results in irregular stoppages and poor surface finish.

▪ TM2501 is available with the MF4 chipbreakersolution, a geometry designed to manage chips effectively and optimize the cutting process to improve reliability and efficiency for your stainless steel machining.


Poor Surface Finish

Poor surface finish and the resulting increase in scrap rates can be the result of unfavorable chip control or unreliable insert wear.

▪ The M3 chipbreaker geometry for roughing and the FF1 for finishing, both available with the TM3501 grade, manage chips effectively to optimize your cutting process.


Excessive Notch Wear on Inserts

A work-hardened layer or oxidation skin caused by unmachined castings can create excessive notch wear, which destabilizes the cutting edge, accelerates wear and reduces the uptime consumption of inserts.

▪ The new Duratomic® TM grades are proven to minimize notch wear for a stable and cost-effective machining process.


Poor Machinability

The poor machinability of especially difficult stainless steel alloys, such as duplex stainless steel, increases production costs.

▪ The new TM3501 inserts, optimized for duplex stainless steels, improve your efficiency and reduce your machining costs by increasing tool life.


NEW DURATOMIC® GRADES FOR TURNING IN STAINLESS STEELS MATERIALS

Copyright © 2019 Seco Tools AB8


TMx501 Grades in Summary

▪ Primary Use: The new Duratomic grade chain, TM1501, TM2501 and TM3501, is directed towards stainless steel turning (ISO-M stainless steel workpieces).

▪ TM1501 offers high productivity in continuous cuts in austenitic stainless steels (SMG M1-M3).

▪ TM2501 is the versatile first choice in austenitic stainless steels (SMG M1-M3).

▪ TM3501 serves as the primary choice for difficult (duplex, super-austenitic, super duplex) stainless steels (SMG M4-M5).

M


TMx501 Grades in Summary

▪ Secondary Use: The new Duratomic grade chain, TM1501, TM2501 and TM3501, complement the TP grade chain in steel turning (ISO-P steel workpieces).

▪ TM1501 handles operations with low cutting speeds or when a high-quality surface finish is required.

▪ TM2501 acts as a tougher alternative to TP3501 in heavy intermittent steel turning.

▪ TM3501 compliments as the toughest alternative in steel machining together with TP40.

P


TM1501

TM2501

TM3501

TOUGHNESSWEAR RESISTANCE

HE

AT

RE

SIS

TAN

CE

(v c

, f

x a

p)

CP500

Grade Positioning

A complementary

proved PVD-grade

M

Stable Semi-Stable Unstable


APPLICATION AREA



TM1501 – Application Area

TM1501 – The Productivity Grade

▪ For medium to large-sized austenitic stainless steel components (SMG M1-M3)

▪ Offers speed, productivity and wear resistance in stable continuous cut applications with medium to large-sized components (ø100-150 mm/4"-6" or larger)

▪ Secondary usage in steel (SMG P2-P8), including ferritic and martensitic stainless steels (SMG P11) at low cutting speeds or for specific surface requirements


Reference (Seco)

WNMG080412-M5 TM2000

Comment: Tool life doubled, with TM1501 producing an

average of 110 pieces per edge compared to

55 pieces per edge with TM2000.

TM1501 – Continuous Cut

Seco

WNMG080412-M5 TM1501

Application: External and face roughing (peeling)

Component: Ring

Material: SMG M2, AISI 316

Machine: Muratec

Coolant: Yes

Tool life criterium: Surface finish

Cutting data: vc = 200 m/min

f = 0.3 mm/rev

ap = 3 mm

Average no of parts

0

20

40

60

80

100

120

TM2000 TM1501


TM2501 – The First-choice Grade

▪ The first choice for low to medium-alloyed austenitic stainless steel (SMG M1-M3)

▪ For moderate/high cutting speeds in continuous cuts or light interruptions for medium to large-sized components (ø100-150 mm/4"-6" or larger)

▪ Complements in steels (SMG P2-P8), especially with severe interruptions



Reference

Insert: WNMG080412-... M25 CVD-grade

Comment: TM2501 delivered +40% more parts than the

competitor insert with clear Used-Edge Detection.

TM2501 – Roughing Austenitic Stainless Steel

Seco

Insert: WNMG080412-MF4 TM2501

Application: Roughing, O.D. turning, copying and facing

Component: Countersunk body

Material: SMG M3, SS-R-316-63.5

Machine: Mazak QUICK TURN NEXUS 350-I

Coolant: Flood



f = 0.25 mm/rev

ap = 3 mm

Time in cut: 1 min, 6 sec per part

0

5

10

15

20

25

Reference MF4, TM2501

Average tool life, no of parts

MF4 - after 16 parts


Component: Ring (forging)

Material: SMG M2, ASTM A182 F347

Application: Roughing, O.D. turning and facing

Machine: Doosan multi-tasking machine

Coolant: High pressure (55 bar, emulsion 8%)



f = 0.21 mm/rev

ap = 2.5 mm

TM2501 – Roughing Austenitic Stainless Steel

0

2

4

6

8

10

12

Reference M5, TM2501

Average no of parts

VB= 1 mm VB= 0.5 mmReference SECO

Insert: CNMG120408-…, M25 CVD-grade Insert: CNMG120408-M5 TM2501

Comment: TM2501 produces 20% more parts than

reference insert at moderate cutting speeds

and clear Used-Edge Detection.


TM3501 – The Sturdy Multipurpose grade

▪ Designed for the toughest stainless steel applications

▪ Ideal for difficult high-alloyed stainless steels, stretching from duplex to super-duplex (SMG M4-M5)

▪ Excellent grade for finishing in various alloys

▪ Low cutting speed or interrupted cuts in SMG M1-M3

▪ Versatile grade offers acceptable performance across all stainless steels



Component: Sleeve ø75 mm (3")

Segment: Oil and gas industry

Material: SMG M4, ASTM A790

Operation: O.D. finishing

Coolant: Flood emulsion



f = 0.35 mm/rev

ap = 0.25 mm

Time in cut: 20 sec per part

Reference: SECO SECO

Insert: WNMG080408-MF4 CP500 Insert: WNMG080408-MF4 TM3501

0

25

50

75

100

125

150

175

MF4, CP500 MF4, TM3501

Tool life, average no of parts

TM3501 – Finishing Duplex Stainless Steel

Comment: TM3501 produced 100% more parts with no sacrifice

in part quality or process safety. To achieve the

specific surface finish required, the feed rate is set at

a relatively high level.


TM3501 – Interruptions and Low vc

Component: Adaptor (nipple)

Material: SMG M2, austenitic stainless steel,

1.4571, X6CrNiMoTi-17-12-2

Operation: Roughing with interrupted cuts

Coolant: Flood

Tool life criterium: Burr formation


f = 0.2 mm/rev

ap = 2.5 mm

ø69

Reference SECO

Insert: CNMG120408-..., M35 CVD-grade Insert: CNMG120408-MR3 TM3501

0

10

20

30

40

Reference MR3, TM3501

Tool life, no of parts

35 parts

18 parts

ø45

Comment: TM3501 shows its strength in applications with

interruptions and with low cutting speeds. Produces 100%

more parts compared to the Referece. The MR3

chipbreaker is particularly strong and reliable in this tough

application featuring hexagonal bar stock.


CP500 – Application Area

CP500 – The PVD Grade

▪ Small parts (ø50 mm/2" and smaller)

▪ Severe interruptions in various stainless materials

▪ Short time in cut

▪ Low/moderate cutting speed (vc)

▪ Low cutting parameters (ap < 1 mm and f < 0.20 mm)

▪ SMG P12 materials, complemented by CP200, TS2000, TS2050, TS2500 and TH1000.


Component: Rod end cell

Material: SMG P12, 15-5PH

Application: OD turning, facing and profiling

Machine: Mazak i-400ST

Coolant: Flood


Cutting data: vc = 76-122 m/min

f = 0.20-0.36 mm/rev

ap = 1.0-2.5 mm

CP500 – 15-5PH, Intermittence and Low vc

Reference

CNMG120408-…, CVD-grade

Seco

CNMG120408-MF3, TM2501,TM3501

CNMG120408-MF4, CP500

0

1

2

3

4

5

6

Reference TM3501 TM2501 CP500


Comment: PVD-grade, CP500, produces 65% more

parts against TMx0501 and reference

CVD-grades at low cutting speed and

interruptions


CP500 – Short Time in Cut and

Low Cutting Parameters

Component: Cover

Material: SMG M2, 1.4301

Application: I.D. turning and facing

Coolant: Flood (emulsion 8%)


Cutting data: vc = 75-120 m/min

f = 0.1 mm/rev

ap = 1.5 mm

ø3

9ø

33

0

200

400

600

800

Reference TM1501 TM2501 TM3501 CP500


Comment: CP500, a PVD grade, outperforms any CVD grade, even latest

Duratomic grades, in a typical application: turning a small

component with little time spent in the cut, limited cutting

speeds and low ap and f.

Reference

DCMT11T304-… , PVD-grade

Seco

DCMT11T304-MF2,

TM1501,TM2501,TM3501,CP500


CHIPBREAKERS



MF4 – First Choice for High Productivity

Strengths

▪ Excellent chip control

▪ Easy cutting geometry with low cutting forces

▪ Long and predictable tool life

Application areas

▪ Medium-roughing

▪ Continuous cut to lighter intermittence

▪ Pre-machined or other easier surface conditions

▪ Proven wiper options


FF1 – For finishing M3 – For medium-roughing MR3 – For medium-roughing

New Chipbreaker Additions for TM Grades

Excellent finishing chip

control, even in the most

difficult SMG M4-M5

duplex stainless steels

Versatile capability, especially

when medium applications lean

more towards roughing

Exceptional chip control ensures

easy cutting action, even when

performing roughing applications


STAY AHEAD OF THE COMPETITION



All TM grades have Used-Edge Detection, a chrome-colored coating that makes it very easy to identify unused edges with the naked eye.

Used-Edge Detection

Did you know that our surveys have indicated the average

shop leaves between 10-20% of its edges unused?


Guidance – Digital Tools

Seco Suggest and Product Search at secotools.com


Guidance – Digital Tools

Search PageType in competitors’ grade or chipbreaker.

Result PagePresents Seco’s best choice, as

well as more wear/heat resistant

and tougher alternatives.

▪ The Seco Compare application is an easy tool that allows you to use a competitor’s product to find the equivalent Seco grade or chipbreaker. In addition to the closest available Seco product, you can also receive recommendations for grades with greater toughness or wear/heat resistance.

▪ This can be key to understanding a specific application based on the original selection of a competitor’s insert.

▪ The application, an excellent complement to My Pages’ Suggest tool, is available for both iOS and Android devices via the Apple App Store and Google Play stores.

▪ This offers a great start, but in more challenging cases, please contact your Seco representative to find the perfect solution.

Seco Compare App

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