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NEW CERAMIC GRADES FROM ISCAR
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ISCAR has three new ceramic grades and two improved silicon nitride grades' one coated and one uncoated grade.
Ceramic grades with their high degree of hardness and low thermal conductivity allow the inserts to be used at faster cutting speeds with good tool life. High hot-hardness combined with excellent chemical and thermal stability make the ceramic inserts suitable for machining difficult-to-cut materials, hardened steel and cast iron.
Ceramic inserts IN11, IN22, and IN23 are normally used in dry cutting, saving on costs involved in coolant purchase, handling and ecological disposal. The IN11 grade is a white ceramic composed mainly of Al2O3 and ZrO2 oxides. It covers the ISO application range of P01-P10 and K01-K10, and it is recommended for finishing applications on steel and cast iron. Recommended cutting speeds can reach 400 m/min (1300 sfm) on steel and 600 m/min (2000 sfm) on cast iron.
The black IN22 grade is composed mainly of Al2O3 and TiCN. It is recommended for turning of hardened steel, difficult-to-cut materials, and chilled cast iron. It is also recommended for machining high-speed steel and tool steel. Cutting speed when machining hardened steel with 50 HRc can reach 150 m/min (500 sfm). Feeds can reach up to 0.2 mm/rev (.01 ipr). This is the most useful ceramic grade and can be used on most of the difficult-to-machine materials.
The IN23 grade is also a black ceramic, composed of Al2O3 with TiC. It is similar in its application range to silicon nitride and is recommended mainly for semi-finishing and finishing of gray and nodular cast iron. It can also be used in light interrupted applications and in milling at finishing conditions. Tool life in machining gray cast iron is even better than with uncoated silicon nitride.
The uncoated silicon nitride grade IS8 is composed of Si3N4, Al2O3 and Y2O3. It is recommended for turning and milling of gray and nodular cast iron and can be used with or without coolant. In continuous turning with medium cutting speed and in milling of GG25 with coolant, a slightly better tool life is achieved than in dry machining. The IS8 grade is the first choice for roughing and semi-finishing on cast iron.
The gold, TiN CVD coated IS80 grade is mainly recommended for turning cast iron and covers the application range of ISO K01-K20. High cutting speeds of 800 m/min (2600 sfm) are possible. This new grade is very useful in the Automotive industry for the roughing of brake discs and similar components. In turning of large rolls made of high-speed steel, chilled cast iron, or high-chromium alloys, roughing can be performed with grades IS8 or IS80 and finishing with the ceramic IN22.
Inserts made of ceramic and silicon nitride are available in a variety of shapes, with and without clamping holes. Most of the inserts are flat rake, double-sided, with a small negative land to improve cutting-edge strength and fracture toughness.
Within the new tool family, ISCAR offers a wide range of holders for flat rake, top-clamped inserts without holes in addition to standard regular holders with pin- and top-clamp mounting for inserts with holes. All holders have a shim below the insert to protect the tool body.
The new ceramic and silicon nitride inserts from ISCAR offer the best solution for a wide range of applications in turning and milling of cast iron and hardened steel and in roughing and finishing with improved tool life and performance.
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