What’s CERMET

CERMET

CERAMIC + METAL

Both advantages of Ceramic & Metal

What’s CERMET

advantages ?CERMET Triple Advantages

(1) High Speed Availability (+ ~ 25%)(150 – 600 m/min)

(2) Longer Tool Life = High Economy

(3) Excellent Finishing Surface

What’s CERMET area ?

CERAMIC

CARBIDE

CERMETCERMET

Toughness

Wea

r R

esis

tan

ce

Super Micro-Grain Cermet

TN6020

TN6020 Normal

2um

Super Micro-Grain Super Micro-Grain CermetCermet

Super Micro-Grain Super Micro-Grain CermetCermet

Smaller size

PVD coated

Super micro-grain cermet

PV7020

PVD coating with surface smoothnessWear Resistance and High Temp. Stability

FS coating (TiAlN) Suitable for high speed machining,Good wear resistance

Super micro grain cermet (TN6020)Good wear resistanceGood crack resistanceHigh strengthSuper micro-grain composition

PV7020TiN coatingChip removal, distinction for used edge

2μm

•Mixed CeramicMixed Ceramic

•A65A65

Soft and Hard Turning 40-60 HRcSoft and Hard Turning 40-60 HRc

Roughing (vc = 250 - 500 m/min)Roughing (vc = 250 - 500 m/min)

•Coated CeramicCoated Ceramic

•A66NA66N

Hard Turning 58-67 HRcHard Turning 58-67 HRc

Roughing and finishing (vc = 150 - 400 m/min)Roughing and finishing (vc = 150 - 400 m/min)

Coated Ceramic A66N

= Features =

1. A66N’s Minute and Unified grain contribute to its excellent Wear resistance and toughness.

A66N Conventional

2. Improved physical properties Bending strength Hardness Anti-oxidation A66N 1,000 20 2.1 Conventional 800 19 2.8

Coated Ceramic A66N

= Advantages =

1. Against conventional CERAMIC

= Stable machining with its excellent quality

2. Against CBN tools

= Can cover some CBN machining area, which means great cost down.

Coated Ceramic A66N

= Applications (Against CBN) =

What is the suitable application or workpiece, which A66N can show its advantage ?

1. Hardness ; Available up to HRC 60 - 65

Let’s try A66N against CBN at Automobile industryAutomobile industry !!

and OPEN NEW MARKETOPEN NEW MARKET !!!

2. Material ; Hardened steel, Die steel, Sintered material..

3. Parts ; Gear blanks, Crank shaft, Valve sheet, Compressor turbin…… ( Mostly for Automobile parts. )

Coated Ceramic A66N

= Test Data 1 (Toughness comparison) =

Nos

e w

ear

(mm

)

Time (min.)

SKD11(HRC60)V=100 m/mind=0.5mm, f=0.2mm/revCNGA120408, WET

Company A

•Megacoated CeramicMegacoated Ceramic

•PT600MPT600M

Hard Turning 58-67 HRcHard Turning 58-67 HRc

Roughing and finishing (vc = 150 - 400 m/min)Roughing and finishing (vc = 150 - 400 m/min)

MicrostructureMicrostructure

PT600M （ KT66 ） Conventional

Fine structure prevents sudden failure

High oxidation resistance prevents flaking

Good chemical stability brings good wear resistance

High fracture toughness brings stability in low speed interrupted cutting

Hardened steelHRC ～ 60

Continuous Interruption

High speed60 ～ 150m/min

PT600M cBN

Low speed～ 60m/min

PT600M Coated carbide

Cast Iron Continuous

Interruption

High speed300m/min ～

PT600M PT600M

Low speed～ 300m/min

PT600M A65

1500

2000

2500

3000

3500

4000

300 500 700 900 1100 1300

Hard

ness

(H

v)

TiCN

TiN

Oxidation temperature (℃) 　

TiAlN

300 500 700 900 1100 1300 　Oxidation resistance(≧1000℃ ） ⇒ Reduce oxidation wear and

diffusive wear

Special Coating Special CoatingSpecial Coating

Cuttig Time (min)

Nos

e w

ear

(mm

)

Cutting conditions ： vc=100m/min, ap=0.2mm, f=0.1mm/rev, wetWork piece ： SCM415H (Case Hardening) (HRC=58 ～ 62)

0.00

0.03

0.06

0.09

0.12

0.15

0 5 10 15 20 25 30 35

cBN AcBN B

PT600M(KT66+MEGACOAT)

A65+MEGACOAT

A65KT66

Cutting conditions ： vc=100m/min, ap=0.2mm, f=0.1mm/rev, DryWork piece ： SCM415H (Case Hardening) HRC=58 ～ 62

Cuttig Time (min)

Nos

e w

ear

(mm

)

0.00

0.03

0.06

0.09

0.12

0.15

0 5 10 15 20 25 30 35

cBNA

cBN B

A65

KT66

A65＋MEGACOAT

PT600M(KT66+MEGACOAT)

0 2000 4000 6000 8000

A65

A65+M

A66

A66+M

　 Number of hits 　

Cutting Condition ： vc=150m/min, ap=0.2mm, f=0.15mm/rev, dryWorkpiece ： SCM415H (Case Hardening) HRC=58 ～ 62

PT600M(KT66+MEGACO

AT)

KT66

A65+MEGACOAT

A65

Cast iron MachiningCast iron MachiningRoughingRoughing

With Silicon Nitride !With Silicon Nitride !

KS6000 / KS500 / KX207KS6000 / KS500 / KX207

* Silicon Nitride Ceramic Silicon Nitride Ceramic for roughing and semi finish

* Both, Wet and DryWet and Dry is possible

* Cutting Speed Range ( 700 - 1600 m/min700 - 1600 m/min )

* Stable and Long tool lifeStable and Long tool life

CBN

New CBN generation is comming! KBN510 & KBN525(Micro Grain structure)

KBN10NBB-KBN25NBB new CBN

• KYOCERA CBN – BB chip breaker• KYOCERA CBN : KBN 10 N and KBN 25 N >> BB – Geometrie• Inovative combination of CBN-application and Carbide-geometrie.• Good chip control by surface hardened steel (40HRC).• Chip breaker geometrie for chip transportation and chip forming.• 3 CBN-sizesfor certain application.• 2 coated CBN – grades• Without coolingl• KBN 10N > finishing – continuous and light interrupted cut

• 100 bis 180 m/min• KBN 25N > Semi-finishing – continuous to heavy interrupted cut

• 80 bis 170 m/min• Application example CrMo – Steel , 15CrMo5• Steel with 60 HRC• ap (mm) f (mm/U) Important!• BB1 0,1 - 0,5 0,05 - 0,15 Description example CNGM 120404/08/12 BB1• BB2 0,2 - 0,6 0,1 - 0,17 TNGM 160404.....• BB3 0,3 - 0,7 0,12 - 0,2 DNGM 150404...BB3 KBN 10• Steel with 40 HRC• BB1 0,1 - 0,5 0,1 - 0,2• BB2 0,3 - 0,8 0,15 - 0,25• BB3 0,5 - 1,1 0,2 - 0,3

NewNew

““Cell Fiber Structure Cell Fiber Structure Ceramics Composite Materials”Ceramics Composite Materials”

““Cell Fiber Structure Cell Fiber Structure Ceramics Composite Materials”Ceramics Composite Materials”

Core / Shell

Diamond / WC-Co for Drilling Application

Si3N4 / BN (Sinboron ) for Turbine Engine ZrB2 / BN (Zirboron ) for Rocket & Solar Thermal Propulsion HfB2 / BN (Hafboron ) for Rocket & Solar Thermal Propulsion

HfC / WRe for X-Ray Target & Rocket Propulsion

WC-Co / Ni for Concrete & Steel Cutting WC-Co / W-Ni-Fe for Drilling Application

etc.

® ® ®

Core (Gray area)

Shell (White area)

Cell Fiber Structure

Cell Fiber TechnologyCell Fiber TechnologyCell Fiber TechnologyCell Fiber Technology

Cell (Minimum unit)50um

Multi fiberLength : 3mmDiameter : 1mm

In-house test of CF1 In-house test of CF1 In-house test of CF1 In-house test of CF1

Random　packed

Surface

200μm

CoreHigh Hardness ….. Wear resistance

ShellHigh Toughness ….. Chipping Resistance

Indentation Test (Vickers Hardness)

Crack propagation resistance

Cell fiber technology Cell fiber technology

Cutting performance can be controlled by changing the combination.

Performance of CF1 (KX213) in Ni based alloymachining is good at higher cutting speed (500m/min)for finishing application such as less than ap 1.5mm.

Lower cutting speed is also available such as 200-300m/min.

However, to show the difference against WG300 (Wisker),werecommend higher cutting speed.

We recommend workpiece material hardness need to beunder HRC 45.

To choose suitable edge preparation is very important

ConclusionsConclusionsConclusionsConclusions

Thank you for your attentionThank you for your attention

VIA DELLA GERBOLA 10/AVIA DELLA GERBOLA 10/A

1007110071CERETTACERETTA

di s. Maurizio C.se (TO)di s. Maurizio C.se (TO)

011 9279348011 9279348

faxfax

011 9244206011 9244206

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