KYOCERA New Products 2014

Introducing the newly completed CA5 series of CVD-coated grades for steel. In addition to CA515 and CA525 for long tool life and stable steel machining, CA510 is now available for high-speed machining, and CA530 for heavy interrupted and high-feed machining completes the new lineup.

Let’s take a closer look at the key advantages of the CA5 series. First is high coating-film adhesion. Interface strength has improved by 40% over the conventional grade. Second, high hardness and toughness in the alpha-aluminum-oxide layer provide longer tool life. Third, a smooth, uniform surface generates low cutting forces and prevents chip welding, which can lead to fracturing. Fourth is a new carbide substrate with improved deformation resistance at high temperatures. This allows high-efficiency machining with 10% improved high-temperature hardness. Finally, the completion of the series of PG, PP, and PQ chipbreakers.

The PG chipbreaker is for medium and rough machining. It is a solution for chip compacting and improves chip control during low- and high-feed machining. It also controls crater wear through a twin-dot structure. In this case study, CA525 and the PG chipbreaker provided longer tool life than a competitor product.

The PP chipbreaker for finishing prevents chip compacting and tangling at small depths of cut with increased feed rates. The PQ chipbreaker for finishing and medium machining reduces chip compacting and cutting force. These three chipbreakers create an effective combination to cover a broad range of steel machining applications. Give the CA5 series an opportunity to advance your productivity.

The PP chipbreaker is available in positive-rake geometries for steel machining. It promotes stable machining by solving problems such as productivity decline due to chip entanglement. Its performance is stable and reliable due to high edge strength. The composite-dot chipbreaker design improves chip control in various applications.

The PP chipbreaker breaks steel into fine chips, preventing them from becoming entangled in the hole. No chips remain in the workpiece after machining. A competitor’s chipbreaker generates irregular chips, but PP generates consistent chips even while increasing the feed rate. When machining soft steel, PP maintains stable chip control. This case study shows excellent chip evacuation. The PP chipbreaker is offered in multiple insert grades for a wide range of steel machining applications and has the potential to improve finishing operations.

The MFH for high-efficiency and high-feed machining. The MFH cutter reduces chattering and is available for a wide range of applications. Convex-edge design reduces cutting forces at initial impact with the workpiece.

The MFH has three types of inserts for a variety of machining options: GM for general use, LD for large depths of cut, and FL with a wiper edge. The GM-type insert is the first recommendation for general use. It is suitable for cycle-time reduction. In this comparison with a conventional-style cutter, the GM-type insert shows superior machining efficiency. A case study shows excellent performance compared to the competitor. The GM-type insert is available for various applications, such as helical milling, plunging, and ramping.

The LD-type insert is suitable for both large depths of cut and high-feed machining. When removing scale from a workpiece, the first pass is at a large depth of cut, but high-feed machining is available from the second pass.

The FL-type insert is suitable for smaller machining centers with low rigidity. It has a wiper edge for finer surface finishes.

For insert grades, in addition to PR1525 for steel and PR1510 for cast iron machining, we have CA6535 for nickel-based heat-resistant alloys and martensitic stainless steel, and PR1535 for titanium alloys and precipitation-hardened stainless steel. This wear-resistance comparison shows slower wear progression after machining for the same amount of time.

Face mills, end mills, and modular heads are available to cover a variety of machining requirements. Consider the MFH for the future of high-efficiency and high-feed machining.

The MRX radius cutter for lower cutting forces and high-efficiency machining is now available. Positive-type inserts and a helical cutting edge with a maximum axial rake of 10 degrees allow low-cutting-force machining. Comparison data shows lower cutting forces. A flat-mark structure holds the insert firmly in place and prevents it from spinning during machining.

The MRX is available for various applications. The lineup includes the GM chipbreaker for general use, SM for low cutting forces, and GH for heavy machining. Both M-class and G-class GM inserts are available. Insert grades include PR1525 for steel, PR1510 for cast iron, CA6535 for nickel-based heat-resistant alloys and martensitic stainless steel, and PR1535 for titanium alloys and precipitation-hardened stainless steel. Wear-resistance comparisons show superior performance, and case studies show improvements in tool life. In addition to face mills and end mills, modular heads are available. Choose the most suitable one for your application. Try the MRX radius cutter for lower cutting forces and high-efficiency machining.

The newly released MRW cutter is a high-efficiency, multi-corner radius type with an economical eight-edged insert design. The cutting edge is sharp and strength has been improved due to a double-edge design. Try the new MRW economical, highly efficient, double-sided insert for various workpieces.

The EZ Bar lineup has expanded with EZ Bar Plus. EZ Bar Plus offers cost efficiency with the benefits of indexable tooling on a high-precision solid boring bar: 60% shorter setup time and excellent repeatability of edge height and tool length. In addition to steel, solid carbide bars are available for long-reach applications.

The 3D sharp-edge chipbreaker series for automatic lathes includes the chip-control-oriented GQ, GF, and CF breakers.

Two new chipbreakers have been released: the low-cutting-force-oriented CK breaker and the sharp-edge SK breaker with good chip control.

Kyocera can solve your chip-control issues in small-parts processing.

Kyocera has a large lineup of quality tools to increase productivity. Additional products include KGD cutoff holders for automatic lathes, with a new holder for the sub-spindle. The MGB face-grooving lineup has expanded, including a GH breaker for high-feed machining and an integral-type toolholder. A new CBN insert grade is introduced; a stable, sharp cutting edge reduces burrs on the workpiece.

Kyocera can increase your productivity through high-efficiency and precision processing.