Effective Machining of Heat Resistant Super Alloy Materials

In Booth 2822, NTK Cutting Tools USA (Wixom, MI) will showcase Bidemics, an industry-changing material with increased toughness used in their JX1, JP2, and new JX3 inserts to effectively machine heat resistant super alloy (HRSA) materials like Inconel 718 and Rene 65 at speeds of 1,600 SFM for increased productivity. When run at typical whisker ceramic speeds, JX1 and JX3 grades easily achieve double the tool life over whisker grades, but Bidemics shines through at increased speeds. For finishing operations, it achieves 10X to 15X higher speed capability over carbides and better wear and notch resistance than CBN. Also on display will be SX3, the new SiAlON grade that exhibits the ideal combination of wear resistance and toughness for machining the newest generation of HRSA work materials (Rene, Waspaloy) and most common materials (Inconel 718). The SX3 grade is effective at roughing and semi-finishing operations for turning and milling applications, using RCGX, RNG, RPGX, SNG, SNGX geometries. Its superior strength is apparent with the insert’s boundary wear resistance, which results in longer tool life compared to competitor grades.

Also on display will be new Solid Ceramic End Mills that achieve up to 20X higher productivity compared to carbide end mills when machining HRSA materials, such as Inconel 718. Newly released 4-, 6-, and 8-flute end mills incorporate specific edge designs that can machine cast iron parts with superior results. The extreme performance is achieved with combined characteristics of durability from the SX9 ceramic grade and toughness built into the unique flute edge design for excellent chipping resistance and long tool life. The balance of toughness and wear resistance enables the end mill to machine even the most demanding applications. NTK has also developed TFX front turning carbide inserts (wiper available) for Swiss CNC applications, capable of one-pass machining of large depths of cut up to 0.197 in. These inserts incorporate a special chip-breaker with a sharp cutting edge for excellent chip control and surface finishes. Corresponding TFT series holders use a rigid side screw clamp that ensures stable turning by preventing movement of the insert from Z-directional cutting forces. TFX inserts paired with a coolant through holder (TFT…-OH) improve chip evacuation, surface finish, part tolerance, and tool life.

Also on display will be new super tough ST4 PVD-coated carbide grade inserts. The thick CrAlN coating provides high hardness and oxidation resistance that solves issues related to machining stainless steels, such as 304SS. High speed machining applications with ST4 inserts have proven results with stable machining, excellent surface finishes, and extended tool life. This super tough coating, combined with NTK chip-breakers for front turning, back turning, grooving, cut-off and ID turning, will exceed machining expectations. Also on display will be S-Mill Series carbide end mills, the latest addition to NTK Swiss Tools. The sharpness of these end mills reduces the occurrence of burrs, produces remarkable surface finish, and improves tool life to outperform the competition. S-Mills are available in 2-, 3-, and 4-flute designs with a range of diameters to cover a wide variety of applications (2-flute available in 2 mm diameter) and in 40 mm, 45 mm and 50 mm lengths that are ideal for automatic lathes. The AC3 (TiAlN coated) carbide grade is ideal for side milling, slotting, and profiling in steel and stainless steel materials.

NTK Cutting Tools USA division of NGK Spark Plugs (USA), Inc., 46929 Magellan Drive, Wixom, MI 48393, 248-668-0100, Fax: 248-668-0200, ctinfo@ntktech.com, www.ntkcuttingtools.com.