|
Iron |
#1Roughing
Ductile #2Facing
Cast
#3Roughing
Cast
#4Roughing
Cast
#5Roughing
Gray Cast
#6Roughing
Cast #7Roughing
Cast
#8Finishing
Cast
#9Finishing
Ductile
#10Finishing
Ductile
#11Boring
Ductile #12Grooving
Cast #13Facing
Cast
#14Cutting
Cast
#15Cutting
Cast
#16Cutting
Cast
#17Cutting
Cast #18Cutting
Gray Cast, #19Roughing
Cast, #20Facing
Nodular, #21Roughing
28% Chrome Cast |
| |
|
|
Steel |
#1Finishing
Steel #2Roughing
Inconel 625 #3Hard
Turning Steel #4Finishing
Stainless Steel |
| |
|
|
Return to top |
#1
- Roughing Ductile Iron |
|
Romay
Tooling
NTK |
| Cost Per
Tool: |
$6.72
$8.13 |
| Tool: |
CNMA 433 T7 CC-513
CNGA 433 T00820 SX8 |
| Parts
per Edge: |
70
35 |
|
Cutting Conditions |
| Cutting Speed: |
1600 SFM
1600 SFM |
| Feed: |
0.014" IPR
0.014" IPR |
| Depth of Cut: |
0.150" DOC per side
0.150" DOC per side |
| Results |
| Annual
Labor Savings: |
$21,300.00 |
| Annual
Hard Cost Savings: |
$20,320.00 |
| Distributor
Salesmen Report (names removed) |
| Distributor has
history dating back to 2001 showing customer has used the NTK CNGA
433 GRADE SX8. It is used as a rough turn in the fabrication
of hydraulic pump bodies. The insert was changed every 30-35
parts, this depending on the size of the block. The 30-35
pieces was a number decided upon by the customer's engineers to keep
the lathe running. 30-35 parts kept the customer in the realm
of other tool changes, thus most inserts were changed at the same
time.
This is the insert in the Lathe that was changed the most.
The NTK insert could reach maybe 50 pieces, however customer thought
that would generate less production, with the machine being shut
down more often. We did test the NTK SX1 grade as well.
We still were nowhere close to a 60 or 70 part tool change.
Testing of a competitors insert had to double tool life to stay
within the realm of other tool changes. It took a couple
different grades and hones, but Romay was successful. We ended
up with a CNMA 433 T7 CC-513 Romay insert. We are reaching the
next plateau of tool changes and have had no issues of premature
failure that I am aware of. |
| |
|
|
Return to top |
#2
- Facing Cast
iron |
|
Romay
Tooling
Kennametal |
| Toolholder: |
DSJNR 1.64D
DSJNR 1.64D |
| Insert: |
SNMA 433 T7
SNGA 434 T0820 |
| Insert Grade: |
CC-514
KY3500 |
|
Cutting Conditions |
| Cutting Speed: |
1125 SFM
900 SFM |
| Feed: |
0.012" IPR
0.009" IPR |
| Depth of Cut: |
0.070" DOC
0.070" DOC |
| Results |
| Time Per Part: |
1:17 (minutes)
including down time
1:37 (minutes) |
| Parts Per Edge: |
120
60 |
| Cost
Savings |
| Cost per Insert: |
$7
$12 |
| Parts per Insert: |
960
480 |
| Cost per Part: |
$0.0073
$0.0250 |
| |
|
|
Return
to top |
#3 - Roughing Cast
Iron |
| Operation: |
Turning
& Facing |
| Material: |
Grey cast
iron - heavy interruption |
| Hardness: |
200
Bhn |
| Speed: |
2200
SFPM |
| Feed: |
.012"
IPR |
| Depth-of-cut: |
.100"
DOC |
| Insert: |
CNGA 434
T7
CNGA 434 T7
CC-52-J Romay
Toshiba
FX-105 |
| 1st Edge |
40
25 |
| 2nd Edge |
40
25 |
| 3rd Edge |
40
25 |
| 4th Edge |
40
25 |
| Results: |
The Romay insert
costs less and gave significantly better tool
life. |
| |
|
|
Return
to top |
#4 - Roughing Cast
Iron |
| Operation: |
Turning
Pulley's |
| Material: |
63000 Grey
Cast Iron |
| Hardness: |
187-241
Bhn |
| Insert: |
CNGA 432
T7
CNMA 432
Romay CC-515
(SiN)
Mitsubishi UC-505 (coated carbide) |
Roughing
Speed: |
3500
SFPM
1000 SFPM |
Roughing
Feed: |
.012"
IPR
.016" IPR |
Roughing
Depth-of-cut: |
.180"
DOC
.180" DOC |
| Insert: |
CNGA 432
T7
CNGA 432 T7
Romay CC-515
(SiN)
Kennametal Kyon 3500 (SiN) |
Finishing
Speed: |
4000
SFPM
2500 SFPM |
Finishing
Feed: |
.008"
IPR
.008" IPR |
Finishing
Depth-of-cut: |
.035"
DOC
.035" DOC |
| 1st Edge |
180
40 |
| 2nd Edge |
170
35 |
| 3rd Edge |
185
42 |
| 4th Edge |
182
41 |
| Results: |
Romay SiN significantly outperformed the
Coated carbide in roughing and a competitors SiN in
finishing, At a lower price. |
| |
|
|
Return
to top |
#5 - Rough
turning gray cast iron |
| Operation: |
Rough
Turning |
| Material: |
Grey cast
iron |
| Insert: |
CNGA 433
T7
CNGA 433 T
Romay
CC-513
Valenite Q65 |
| Speed: |
1500
SFPM
1500 SFPM |
| Feed: |
.018"
IPR
.018" IPR |
| Depth of
cut: |
.060"-.080"
.060"-.080" |
| Tool
Life: |
319pcs/edge
289pcs/edge |
| Results: |
Romay grade CC-513 increased tool life by 10% over
Valenite's Q65 at a significant cost savings per
insert |
| |
|
|
Return
to top |
#6 - Rough turning cast
iron |
| Operation: |
Turning
brake drums |
| Hardness: |
180-200
BHN |
| Insert: |
CNGX 454
T7
CNGX 454
T
CNGX 454 T
CC-515
SPK-SL500
Widia |
| Speed: |
2200
SFPM
2200
SFPM
2200 SFPM |
| Feed: |
.018"
IPR
.018"
IPR
.018" IPR |
| Depth of
cut: |
.120"
.120"
.120" |
| Tool
life: |
18parts/edge
18parts/edge
14parts/edge |
| Results: |
Romay grade CC-515 outperformed the Widia silicon
nitride and equaled the SPK-SL500 at a lower cost per
insert. |
| |
|
|
Return
to top |
#7 - Roughing Cast
Iron |
| Operation: |
Facing O.D.
Hub driven |
| Material: |
Grey cast
iron G-3000 |
| Hardness: |
178-239
Bhn |
| Speed: |
2800
SFPM |
| Feed: |
.018"-.024"
IPR |
| Depth-of-cut: |
.060"-.090"
DOC |
| Insert: |
CNGA 433
T02020A
CNGA 433
T02020A
CC-513
(SiN)
Kennametal Kyon 3500 (SiN) |
| 1st Edge |
107
100 |
| 2nd Edge |
69
74 |
| 3rd Edge |
100
52 |
| 4th Edge |
56
90 |
| Results: |
Romay SiN grade CC-513 cost less & ran
equal to Kennametal's Kyon 3500. |
| |
|
|
Return
to top |
#8 - Finishing Cast
Iron |
| Operation: |
Boring |
| Material: |
Class 30
cast iron cylinders |
| Hardness: |
187-200
Bhn |
| Speed: |
3300
SFPM |
| Feed: |
.012"
IPR |
| Depth-of-cut: |
.015"
DOC |
| Insert: |
SNGA 433
T7
SNMA 433 T7
CC-52-J
(SiN)
Toshiba FX-105 (SiN) |
| 1st Edge |
150
150 |
| 2nd Edge |
150
150 |
| 3rd Edge |
150
150 |
| 4th Edge |
150
150 |
| |
3
offsets, 8 tight
bores
8 offsets, 16 tight bores |
| |
All inserts
were changed at 150pcs. |
| Results: |
Romay grade CC-52-J equal to FX-105 but had
less offsets and tight bores. |
| |
|
|
Return
to top |
#9 - Finishing
Ductile Iron |
| Operation: |
Turning,
continuous cut |
| Material: |
Ductile
Iron |
Finish
Required: |
.5 to .6
(metric) |
| Speed: |
3500
SFPM |
| Feed: |
.008"
IPR |
| Depth-of-cut: |
.011"
DOC |
| Insert: |
CNGA 432
T2
CNGA 432 T
CC-20 (black
ceramic)
NTK-HC1 (white
ceramic)
NTK-HC2 (black
ceramic)
Sandvik cc690 (SiN) |
| Tool
life: |
40-45
parts/edge
5 parts/edge |
| Results: |
Romay black ceramic significantly outlasted
the competitors black and white ceramic. It even outlasted a silicon
nitride, plus it cost less than the competition.
|
| |
|
|
Return
to top |
#10 - Finishing
Ductile Iron |
| Operation: |
Turning
brake drums |
| Material: |
Ductile
Iron |
| Insert: |
TNGA 434
T2
TNGA 434 T
CC-20 (black
ceramic)
Valenite SU-310 (coated carbide) |
| Speed: |
660
SFPM
660 SFPM |
| Feed: |
.010"
IPR
.010" IPR |
| Depth-of-cut: |
.020"
DOC
.020" DOC |
| Tool
life: |
320
parts/edge
55 parts/edge |
| Results: |
Romay black ceramic significantly outperformed
coated carbide by lasting almost six times
longer. |
| |
|
|
Return
to top |
#11 - Boring ductile iron
hub |
| Operation: |
Rough
boring, with varying hardness |
| Tool: |
4.5" step
bore X 4.5" long |
| Insert: |
CNGA 433
T7
CNGA 433 T
Romay
CC-513
Kennametal Kyon 3500 |
| Speed: |
550
SFPM
550 SFPM |
| Feed: |
.012"
IPR
.012" IPR |
| Depth of
cut: |
.070"-.200"
.070"-.200" |
| Tool
Life |
6.5pcs/edge
4.75pcs/edge |
| Results: |
Romay CC-513increase's tool life by over 36%
compared to the Kyon 3500. At a much lower price per
insert. |
| |
|
|
Return
to top |
#12 - Grooving Cast
Iron |
| Operation: |
Grooving |
| Material: |
Dura-Bar 6880 cast iron |
| Insert: |
RM 1200
T7
RM 1200 T7
CC-20 (black
ceramic)
Manchester uncoated C2
carbide
#508-156 |
| Speed: |
1800
SFPM
450 SFPM |
| Feed: |
.004"
IPR
.004" IPR |
| Tool
life: |
100-120
pieces/edge
10-12 pieces/edge |
| Results: |
Romay black ceramic grade CC-20 ran three
times as fast and lasted ten times longer. |
| |
|
|
Return
to top |
#13 - Rough facing cast
iron |
| Operation: |
Facing cast
iron brake rotors |
| Insert: |
CNGA 433
T
CNGA 433 T
CC-53
FX-105 |
| Speed: |
2200
SFPM
2200 SFPM |
| Feed: |
.023"
IPR
.023" IPR |
| Depth of
cut: |
.090"
.090" |
| Tool
life: |
150parts/edge
100parts/edge |
| Results: |
Romay CC-53 gives a 60% increase in tool
life. |
| |
|
|
Return
to top |
#14 - Cutting cast
iron |
| Material: |
Dura-bar
cast iron |
| Insert: |
CNG 454
T3
TPG 322
T3
VNGA 432 T2
CC-10
CC-10
CC-10 |
| Speed: |
2000-2800
600-1200
1000-3300 |
| Feed: |
.008"
.006"
.006" |
| Depth of
cut: |
.002"max
.125max
.125max |
| Type of
cut: |
Rough,
continuous turn
Rough, continuous bore Finish, continuous
turn |
| |
|
|
Return to top |
#15 - Cutting cast iron |
| Material: |
Cast
Iron |
| Insert: |
CNGA 431
T7
CNGA 431
T7
CC-52-J
SX-8
|
| Speed: |
3200
3200
|
| Feed: |
.007"
.007"
|
| Depth of
cut: |
.001"max
.001"max
|
| Pieces/Edge |
110
75 |
| Type of
cut: |
Finish I.D.
Turn and Face Finish I.D.
Turn and Face |
| Results: |
Romay CC-52-J increased tool life per edge by over
46%. |
| |
|
|
Return to top |
#16 - Cutting cast iron |
| Material: |
Cast
Iron |
| Insert: |
CNGA 543
T7
CNGA 543
T7
CC-52-J
KS-6000
|
| Speed: |
2800
2800
|
| Feed: |
.015"
.015"
|
| Depth of
cut: |
.125"max
.125"max
|
| Pieces/Edge |
89
55 |
| Type of
cut: |
Rough I.D.
Turn and Face Rough I.D. Turn and
Face |
| Results: |
Romay CC-52-J increased tool life per edge by over
62%. |
| |
|
|
Return to top |
#17 - Cutting cast
iron |
| Material: |
Cast
Iron |
| Insert: |
CNGA 432
T3
CNMG 432
CC-5126 COATED
CARBIDE
|
| Speed: |
700
700
|
| Feed: |
.024"
.024"
|
| Depth of
cut: |
.040"max
.040"max
|
| Pieces/Edge |
100
50 |
| Type of
cut: |
CNC
Turning
CNC Turning |
| Results: |
Romay CC-5126 increased tool life by
50%. |
| |
|
|
Return to top |
#18 - Cutting Grey cast
iron |
| Material: |
Grey Cast
Iron |
| Insert: |
VNGA 331
T2
VNMG 331
CC-20
KC9315
|
| Speed: |
2500 900
|
| Feed: |
.0051"
.0051"
|
| Depth of
cut: |
.025"max .025"max
|
| Pieces/Edge |
125
100 |
| Type of
cut: |
Poly Vee
Profile
Poly Vee Profile |
| Results: |
Romay CC-20 increased the speed by 36% and increased
the Pieces/Edge by 25%. |
| |
|
|
Return to top |
#19 - Roughing cast
iron |
| Material: |
Cast
Iron |
| Insert: |
CNGN 434
T7
CNGN 434 T2A
CC-514
GSN
|
| Speed: |
1980
1980
|
| Feed: |
.012"
.012"
|
| Depth of
cut: |
.065"max
.065"max
|
| Pieces/Edge |
32
20 |
| Type of
cut: |
Profile
&
Chamfer
Profile & Chamfer |
| Results: |
Romay CC-514 increased the Pieces/Edge by
62.5%. |
| |
|
|
Return to top |
#20 - Facing nodular
iron |
| Material: |
Nodular
Iron |
| Insert: |
CNGN 434
T7
CNGN 434
T02020
CNGN
434 T2A
CC-514
SL500
GSN
|
| Speed: |
2415
2415
2415 |
| Feed: |
.003"
.003"
.003"
|
| Depth of
cut: |
.038"max
.038"max
.038"max |
| Pieces/Edge |
63
38
40 |
| Type of
cut: |
Facing/profile
Facing/profile
Facing/profile |
| Results: |
Romay CC-514 increased the Pieces/Edge by
61.5%. |