The chain is not stronger than the weakest link 02:18

Regardless of operation, PCBN-grade, workpiece material or stability of the setup, the most important thing to start with before developing an operation is to make sure that the conditions are the best possible. Conditions of tool holders are one of the things that are too often ignored at customers when there are tool life issues.

The tool holder below is one example what was found at a customer where they had problems with breakage of solid triangular inserts when clamping them. Just a quick look into the machine showed this holder which has severe damages probably due to a collision of some kind. The tool life problem was solved just by changing the tool holder to a new one. The whole matter was finished with an education of the machine operators regarding hard turning, PCBN inserts, how to use them and so on.

For more information, please contact your local Seco representative, or our Advanced material (PCBN/PCD/CERAMIC) team.

Author: Stefan G Larsson Fritz Product Specialist SECOMAX PCBN/PCD/CERAMIC SECO TOOLS AB 737 82 Fagersta, Sweden Office +4622340572 Mobile +46761367807 email:stefan.g.larsson@secotools.com

Turning of Aluminium Alloy component 23:24

The main alloying element in Aluminium alloys is Silicon, and the more Silicon is added, the more abrasive the material becomes. This means that the cutting speed has to be adjusted based on the Silicon content.

General recommendations for PCD are:

• Low Silicon (< 8%) Cutting speed 600 – 2,500 m/min
• Medium Silicon (8 to 15%) Cutting speed 450 – 1,300 m/min
• High Silicon (> 15%) Cutting speed 100 – 1,000 m/min

Seco Tools have a range of PCD-grades covering these alloys, from general grades for the low Silicon alloys to grades better suited to handle the abrasiveness of high Silicon alloys.

PCD05 is a grade that has superior performance in machining of these high Silicon Aluminium alloys. It is a small grain size grade with excellent edge toughness and wear resistance.

In a recent project, a high Silicon Aluminium alloy component was machined. The application included axial turning and facing with a RPGW0803M0F-LF insert at the following cutting data:

• Cutting speed 150 m/min
• Feed rate 0.3 mm/rev
• Depth of cut 0.5 mm

The result shows the superior performance of PCD05. Tool life was doubled, and the surface of the component was also more shiny, which was important for the customer.

For more information, please contact your local Seco representative, or our Advanced material (PCBN/PCD/CERAMIC) team.

Author: Henrik Sandqvist Product Specialist SECOMAX PCBN/PCD/CERAMIC SECO TOOLS Shanghai CO., Ltd. Building 4, No 797, Puxing Road, Pujiang Town, Minhang District, Shanghai 201114, China Office: +86 21 5426 5849 Mobile: +86 185 1520 6942 e-mail: henrik.sandqvist@secotools.com