High-performance cutting materials increase productivity for the mass production industry

Kyocera cutting tools for the metalworking industry

September 10, 2005 - Modern cutting materials such as ceramic and cermet are an attractive alternative in the metalworking industry to conventional carbide cutting tools. They can play a significant role in optimising processes and thereby increase productivity and profitability. They cover all uses – from light working to heavy machining. The Japanese technology company Kyocera offers extremely high-performance cutting materials for metalworking made from ceramic and cermet, perfectly in tune with the industry’s demands.

Kyocera cutting tools for the metalworking industry

Under the brand name Ceratip, Kyocera offers cutting tools for working of both soft and tempered steel, working of cast iron steel grade and heavy machining with increased cutting depths and intermittent cutting data. José
Agustín-Payá, Product Marketing and Product Technology Manager for Kyocera Cutting Tools Division, says: “Particularly in the mass production industry, Kyocera’s cermets and cutting ceramics can result in higher production levels and lower costs.” And Agustín-Payá continues: “Thanks to their good resistance to wear and tear, and their high level of toughness, they can help reduce processing times and processing costs for the mass production industry by up to 35%”.
High cutting edge stability through fine grit technology Kyocera’s fine grit cermet – the uncoated TN6020 and the coated PV7020 varieties - surpass the performance of carbide in terms of longevity and processing times. They are used in smooth working, medium working and light rough working. They are characterised by extremely high cutting edge stability, very important for cutting interruptions, and can cover the whole range of uses from smoothing to light roughing of steel. In medium steel working (cut depth 1.5 – 6.0mm, feed 0.10 – 0.50mm/rev.), they are used for cutting speeds ranging from 250 to 600m/min.

Mixed ceramics in use

The Kyocera mixed ceramic A65 (Al2 O3 + TiC Aluminium oxide + titanium carbide) lends itself to uses ranging from soft and hard working to HRc 60 as well as from smoothing to heavy machining (roll turning) of steel. Using the same cutting depth and feed as with carbide, cutting speeds of up to 500m/min can be achieved. For hardnesses greater than HRc 60, the coated
Kyocera mixed ceramic A66N is recommended. With considerably lower costs per blade than CBN and reduced processing time due to higher speeds, mixed ceramics can help to optimise costs.

More profitability with “Sensor Tool”

For better process monitoring in the mass production industry, Kyocera has developed an intelligent cutting insert, with the “Sensor Tool” system. This system detects damage, undue wear and tear and microcracks right at the cutting edge, and gives an appropriate command to the machine controls,
which break off the process. With conventional blades, only 70 percent of the cutting edge is actually used while 30 percent is allowed for as a buffer to ensure the process is safe. The Kyocera cutting insert, however, can use up to 100 percent of its cutting edge thanks to the Sensor Tool
System.This system avoids waste and improves process speed.