Ceramic Cutters cut faster than carbide.
Press Release Summary:
Kyon 2100 grade silicon nitride based ceramic inserts boost productivity 100% to 500% on high temperature alloys by machining at cutting speeds of 3,000 sfm, 10 to 25 times faster than carbide grades. It performs rough milling of nickel, cobalt, and iron based heat resistant alloys, and rough machining of high temperature alloys such as Waspalloy, Haynes 25, Inconel 718, Stellite, and similar materials.
Original Press Release:
New Kennametal Milling Cutters Boost Productivity 100%-500% on High-Temp Alloys
(Latrobe, PA) New Kennametal milling cutters boost productivity 100% to 500% on high temperature alloys by machining at cutting speeds of 3000 surface feet per minute (sfm) and higher with Kyon 2100 grade ceramic inserts. Specially engineered for rough milling of nickel, cobalt, and iron based heat resistant alloys, the Kyon 2100 ceramic material cuts at speeds at 10 to 25 times faster than carbide grades. "In a typical success story with these new cutters and inserts, we took cycle time from 45 hours to 15 hours on an aerospace engine mount," said Tom Hofmann, Product Manager for High Temp Alloy Cutters for Kennametal.
Kennametal's Kyon 2100 silicon nitride based ceramic offers high thermal and shock resistance, making it ideal for rough machining of high temperature alloys alloys such as Waspalloy, Haynes 25, Inconel 718, Stellite, and similar materials. The new technology machines these materials at cutting speeds of 2000 sfm to 4500 sfm and feet rates of 0.002 inches per tooth (ipt) to 0.005 ipt, providing metal removal rates of eight to 15 times faster than those cutters using carbide inserts. "Customers who try these cutters and inserts for the first time sometimes can't believe they can run that fast," said Glenn Sheffler, Standard Products Engineer for Kennametal. "But once they see that the inserts can take it and figure out how much money they can save, they become believers."
A new line of Kennametal shell mills and integral shank end mills are specially designed to take advantage of this ceramic cutting material in face milling, deep pocket milling, and profile milling operations. Shell mills are available with effective cutting diameters ranging from 2" to 4". Integral shank end mills provide effective cutting diameters from 1.25" to 1.5". The cutters' use of one-half inch round inserts provides increased strength and toughness while thinning the chip at the cutting edge. A rugged clamping system secures the insert in the pocket for increased stability at high cutting speeds. Through air capability provides for excellent chip evacuation in dry milling, eliminating coolant costs while improving surface finish.
