A presentation on the cutting-edge applications of PCD, CBN, and ceramic cutting tools.
Robert Navarrete the National Product Manager for Turning at ISCAR USA presents the cutting-edge applications of PCD, CBN, and ceramic cutting tools from Iscar.
Thank you to Iscar for sponsoring our April Manufacturing Lunch + Learn!
Jake Kauffman: Hello, and welcome to the latest lunch, and learn from GIE Media's manufacturing group of magazines. I am Jake Kaufman, and today we are glad to be joined by Iscar, as they will present on the cutting edge applications of PCD CBN. And ceramic cutting tools. Iscar is a full solution provider of metal cutting tool products and accessories for CNC machining.
Launching hundreds of new products for machining each year, Iscar is where innovation never stops. Today we are joined by Robert Navarrete, who is the national product manager for turning Iscar USA. Robert is a seasoned expert in machining and cutting tool applications with a specialized focus on cutting tools and operations. You may ask questions throughout Robert's presentation we will try to ask as or sorry, try to answer as many as possible before we wrap things up today. But without further ado, Robert, the floor is yours.
Robert Navarrete: Thank you for having me here today.
I would like to discuss hard part turning, and the tools that Iscar can provide to help customers streamline their process, become more cost, effective and improve productivity.
So the tools or inserts that Iscar can help provide are PCD CBN and Ceramic.
These are application specific inserts. PCD for your non-ferrous type of materials, your aluminums, your copper stuff like that your CBN. Which can handle your cast iron, hardened steel, high temp alloys, and your ceramic as well, that can handle those same groups, your cast iron, your hardened steels and your high temp alloys.
So one thing I do want to point out is Iscar did come out with a ceramic CBN PCD. Inch catalog which is available on our website.
New for 2025, over 600 new ceramic inserts over 500 new CBN. Inserts, and over 200 new PCD inserts. This is in addition to our pre-existing line. So what this did is Iscar expanded our line more grades, more edge preps, more geometries. So we have a solution to any situation that could be presented to us.
So first, we're going to get into PCD, so with our Iscar PCD line.
PCD. Polycrystalline cubic diamond is the highest on the Vicker harden scale. So this is going to be our hardest piece of cutting, cutting tool. So polycrystalline cubic diamond above CBN and above ceramic.
One thing I do like to point out is diamond, a mineral composed of pure carbon, so this cannot be used on steel and cast irons, because at temperatures above 700°F, carbon atoms react with the part of the material to form iron carbide, and cause the diamond structures to collapse. So these are applications where PCD will not fit. I do like to point that out steel and cast iron is not applicable in PCD. Applications.
Where this PCD does apply aluminum. Our aluminum alloys, our copper alloys, wood composites, plastic glass, rubber, and wood.
If any of the customers or industries you're working with. Do this type of machining or these types of materials. This is where we can plug in PCD to help them be more efficient, more cost effective produce parts faster provide predictability due to the PCD component.
So what Iscar can provide. Iscar has 3 grades that are available for PCD, we have our Id. 5, which is our 1st choice. This is our 80 20 rule. Our Id 5 is going to handle most of the applications. As you see, it's Id. 5 is a PCD. Medium grain. Then we offer an Id. 4, which is a PCD. Fine grain for strong uninterrupted cuts. Ideal for milling operations. But keep in mind this is something we'll plug in. If Id 5 doesn't fit the bill. Id. 5 will fit most of the applications.
Then we have our Id. 8, which is a PCD. Mixed grain used when Id. 5 is inadequate for turning to milling applications. This is a much bigger grain. Size 3 to 25 microns. As you notice the Id. 5 s. Less than 10 microns, the Id. 4 is going to be less than one micron. So the grain structure itself. Id. 5 will fit most of the applications. Our 80 20 rule.
So our grade map for PCD inserts. So we keep in mind. Continuous cut light, interrupted, cut, heavy, interrupted cut. When are we going to apply which grade to which application our Id. 5 and Id. 8 are going to be able to handle your continuous cuts and your light interrupted cuts.
If for some reason, an Id. 5, which is our 1st choice, and an Id. 8. Can't handle those situations. That's when we'll plug in an Id. 4.
These are available. But our 1st choice will be an Id. 5. This is a medium grain, PCD insert for continuous and light interrupted cuts.
So what sets us apart, and what we bring to the table new to the market?
Our chip breakers on our PCD inserts. So a chip breaker formed directly on the PCD. So the fact that we're able to break chips, which was typically a type of insert which will have a hone or a T. Land.
We're actually plugging in chip formers now. So we have an Md. Chip, former PCD with a chip breaker, and we have an Rd. Chip, former on the PCD. The corner radiuses we have available are 18 and 16 thousands. So the fact that we're able to break chips in a non. Ferrous environment is a win-win for everybody. If you're familiar with non ferrous type materials or even plastics where it's a bird nest, no matter what you do, bumping up speed. SFM, increasing feed rates, blasting, coolant flow. You know all the things we try to do to get some type of chip control oscillating the spindle, putting a dwell.
We're adding a chip, former, which is going to help you break chips.
An example of this situation a chip breaker versus a non-chip breaker. It makes a huge difference, especially in non-ferrous type environments. As you can see on the left. No chip breaker on the right chip breaker, same grade, same radius chip breaker, no chip breaker, massive difference. So if you're familiar with non-ferrous type work, and that's the environment you work in, and you're seeing bird nest in your chip. Spin in your chip bin. We have a solution for that
One thing to keep in mind, and we do present to customers or ask customers when they're transitioning from carbide to a PCD is what type of RPM capability we have on this machine. Non ferrous materials spin fast. To begin with. Now we're applying PCD, which is a much harder component than carbide. We're going to spend at higher velocities. So I think something we like to point out in a graph. We do show to customers quite often. So for your aluminum alloys depending on the type of group you're in for semi finishing and finishing. We could be just below 10,000 SFM.
So things we like to ask. But we can also be at the lower end of the spectrum. So as long as we have that range capabilities for what you're doing.
These tools can fly so your aluminum which contains above 12% silicon.
You're going to be a little slower, you know, 2,900, just below 3,000 SFM, so things we like to point out to customers, hey, we have these tools, but we want to make sure that we're not overworking the machine. We have the RPM capability, a secondary chart, and you can see the materials that are applicable to PCD. On the left column. Your copper alloys, your bronze, your brass tinfoil, copper, your zinc, alloys, magnesium, the type of range and type of parameters you can expect to run these tools at just going down towards closer to the bottom. Your glass, your plastic materials, your ceramic, your graphite, these are flying compared to carbide and very predictable, very predictable. You get the high velocity, and then, plus, if we plug in the chip warmers. You're getting high velocity plus breaking chips. So a potential great choice for your non-ferrous environment.
So some examples of stuff we've seen out in the field. These are published test reports. So if you can see aluminum, your cast alloy the id 5 grade it was with a Gida. So it's a grooving tool just under 2,500 Sfm. 4, Ipr. 8th out depth of cut the number of pieces compared to the competitor. We're just under 2,000. The competitor was just above a thousand.
Your aluminum cast alloy bottom right? Id. 5. Now we're using a PDC. So a 332, 9, 400 SFM. 18 inches per Rev. 40,000 depth, to cut just under 10,000 pieces customers roughly around 6,000 pieces. So these are with our Id 5 grade or 80 20 rule grade that will fit most applications.
Then we have our copper alloys in your bottom left your aluminum magnesium same. That's with the Id. 5, as you notice, with the copper alloy, we're about a thousand SFM. And the aluminum magnesium 8,200 SFM, so just note the number of pieces different.
And also I have something I'd like to point out. These test reports are with standard edge Preps. These are not with the chip formers. We can expect tool life to increase with the chip formers. These are standard edge preps a T land.
So that's our PCD. Offering a quick, you know, 40,000 foot view a quick overview. But, Iscar, we do offer PCD. For your non-ferrous environment. If these are application specific where we can plug in and help customers be more productive.
So hard, part turning, machining, so typically Pcbn and ceramic inserts, these are, what are we are going to apply for hard part turning once it goes above 45, Rockwell, we're entering the world of ceramics and CBN, where these tools are going to shine anything below that's too soft. We're not going to be plugging in those CBN and ceramics. That's where that's the world of carbide.
So your main 2 types of inserts for hardened steel and high temp alloys will be ceramics CBN, including the cast iron group os Iscar CBN line.
So polycrystalline cubic diamond Nitride. So now we're a step below on the Vickers hardness scale from PCD. Now. So it's PCBN, also known as CBN. You can hear it 2 different ways in the industry. PCBN and CBN.
So the industries where these are applied, and this is just a small group. There's many others, shafts, gears, pump parts bearings die molds, high speed, steel, hydraulic components and printing rules.
These are industries where they're typically hardened above 50 Rockwell. And this is where we can apply. CBN. So CBN inserts are generally generally used for finishing process. We can use CBN for roughing. But generally typically people will apply these for finishing process.
What a lot of people don't realize is you can get a very, very high finish with CBN potentially bypassing. Having to send these out for grinding. You can get an Ra of 16 or better, always using a fine grain. CBN, we have customers hitting an 8 8 finish or better with CBN. Obviously, we're having to adjust SFM'S deficit cuts and feed rates just as you would with carbide. But you can hit 16 or better. We have customers hitting 8 or better, with a fine grained CBN.
So the coarser, the CBN, the tougher the CBN, just as you would with carbide. You have your hard carbide and you have your tough carbide. Same applies to your CBN. You have your fine grain, which is going to be hard, and you have your coarse grain, which is going to be tough.
So for Iscar how that applies. We have our hard carbide, which is our hard CBN. I should say, which is on the left, and then your tough CBN, which is on the right.
How designation wise or grade wise the lower the number, the harder the Cbn, the bigger the number the tougher the CBN you can use. CBN for, interrupted Cut.
We have CBN with the braised wafers. We have solid top CBNS and we have full solid CBNS. There are plenty of customers that do a lot of interrupted cut, intermittent cut going through micro stamps with CBN. CBNS are very tough. We just need to make sure we have the correct grade and the correct edge prep for the application. And if we're doing finishing work, then we go with the fine edge prep, and a hard piece of CBN we have CBN grades and edge Preps that will apply to each situation.
So speaking of edge Preps, so we will offer different variances. So, for example, we have an S. Which is a chamfer in a home. We have an E with a home, a T with a chamfer, and then a P with a double bevel.
So how that breaks down is, for the example, on the bottom you have an s. 0 4 2 0. That's going to be a 4,000 Tlan with a 20 degree angle. So it's very easy to read.
We also offer metric and imperial versions of this. So you have your standard edge preps, and then we also have semi-standard edge preps or chip formers, and your semi standard. So, depending on what we're applying, we have, we have your I'll head back. You're off the shelf, your standard.
And then we also asked for semi-standard, low cutting forces and strong edge preparation. So metric and imperial. So this is a snapshot out of our imperial catalog. So, depending on what we're doing, say, we have an application.
Hey? We're popping chips. It's curling a little too wide or potentially curling a little too narrow. We can adjust an Ls an S. And le depending on what we're looking at. Same thought process as carbide. Hey, we have a we need a more blunt edge. We need a sharper edge. We need a more high, positive same thought process with edge Preps with CBNS.
So, I keep speaking of edge Preps CBNS with chip breakers. This is something Iscar excels in. We have CBNS with chip breakers. We have an F we have for finishing an M for medium, and R for roughing.
One thing I do like to point out with CBNS with your braised tips. In this fashion the edge prep is by application. This does not apply to the depth of cut as it would with a piece of carbide. You get a piece of carbide and say, Hey, I have a finishing edge. Prep. You're going to take a light depth of cut. You get a carb piece of carbide with a roughing edge. Prep. You're going to take a much larger depth of cut for CBN. This applies to the application, not the depth of cut. You're still limited by the wafer. So if you have scale crust, interrupted Cut you might use a roughing edge. Prep. If we're taking a light depth of cut trying to achieve a 16 or better finish, we use a finishing edge. Prep.
So just an example just like with the PCD, mo chip breaker versus chip breaker night and day.
So we got your bird's nest. We walk into plenty of shops, chip bins huge bird's nest plug in a chip breaker. We're breaking chips. Chips are getting out of the way. We're not recutting chips. We're not rubbing much better finish.
So if we can apply chip breakers to your hard part turning and your high temp alloys, it just makes it a better situation for everybody. Better chip control to chip bins or not having to deal with birds nest quality. You know. They're not worried about what's going on. Everybody's not being safe, having to put on gloves stuff like that. We want to break chips.
So that last video was dry.
So people will ask, Okay, do we run coolant? Or do we not run coolant, so wet? Cutting improves tool life for clean, continuous cut, just as we just said, same thought process, same same ideology as you would apply to like carbide. We have instances where, hey? We're not getting great tool life. Let's shut off. The coolant. Same thing can apply to CBN. But for CBN. For wet cutting improves tool life for continuous cuts. So we want to put the coolant on for clean, continuous cuts for interrupted cut. We want to leave the cooling off. We're going to improve the tool life.
One thing I do like to point out, and this can apply to CBN ceramics actually carbide anything else anytime we're leaving the Coolant off.
We're not cooling that insert as much as it would with Coolant. So we got to keep in mind the screws and the clamps. These are consumable parts that heat's getting transferred into that screw into that clamp. So something to keep in mind. You may want to swap these out periodically, these are consumable, these are wearable parts. So if we're running dry, let's make sure we swap out those screws and swap out those. Swap out those clamps.
So when, to use coolant, clean, continuous cut. Let's throw that coolant on, interrupted cut. Leave the coolant off. If we have air blasts beautiful, just to get the chips out of the way. But let's leave that dry.
So we also have coated CBN. It's going to add an extra thermal barrier to that insert. So it's going to be protected. We're going to be protected from the heat. We're going to get better tool life.
Just so if we have, if we have a clean, continuous cut situation, or where a lot of heat's being applied, or we want to run it dry.
Let's leave the we can run a coated, insert and get extended tool life.
So we do have PVD coated PVD coated. Insert on CBN.
And with the coating grades, as you'll see. So Bi, 0 5 HC. That C. Tells me it's a coded grade. So H. For hardened steel c coated.
So an example. This is a test report that a test we did against a competitor. So it's our Bi. 30 H. So for hardened steel, the cutting speed was 230 SFM. We bumped our feed rate or Ipr to 4 and a half. Ipr. Compared to 3. The depth of cut was 8 thou the tool life was 21.7 life in feet compared to the 10 feet. So we got 2 times longer tool life.
So that was our Cng. A. 4, 31, 2 Mt. So, 2, 2 edges, Bi. 30 H. Versus, and another Cng. A 4, 31 extended tool life.
Another report. So Iscar versus competitor bi. 30 H. Again. This time we're in nickel chromium case, hardening steel 460 Sfm. Just under 4 Ipr. Depth of cut. At 8 thou we had 130 pieces compared to the competitors, 30 pieces 4 times longer tool life, and this is a Tng. 8. So the 3 Mt, so that's going to be 3 3 edges, 3 edges. So 3 Mt.
And that was a nickel chromium case hardening steel.
So that's our CBN said. 40,000 foot view quick overview.
Now we have our ceramic line. So this car ceramic line.
So just a very quick overview our grades overview our offering. This is the new product offering. This car has 15 new grades, your aluminum oxide, your silicon nitride, your cylon, your whisker and bidemics, typically these will apply to aerospace automotive and the steel industries.
So, I like to keep this. Put this chart up in customer seminars. Anytime. I do a presentation like this, a breakdown. The grades, and what groups they apply to, and they're listed top to bottom. So, your Cylon, for example, in the bottom, left top to bottom from hard to tough, so numerically, your is 14 is going to be your hardest piece of cylon for super alloys, and your is 55 is going to be your toughest piece of cylon for super alloys, and same applies across the roads. So I like to show this to customers, distributors, salesmen. Anybody I'm working with saying, Hey, here's our hard to tough chart for ceramics per alloy group.
So won't jump into this too much. But how we are our nomenclature. So cng. 4, 32 a. Wl, we do offer ceramics with a wiper. We do offer ceramics with a chip breaker, so if it had an Ag. It would be a chip breaker. Same thought process as far as the 5th station, or 4 stations. They could have an S for a chamfer, and a rounded home, E. For a home, a T for a chamfer, and a p for a double bevel chamfer plus rounded. So T. 0 4, 2,
So your 0 4 is going to be a 4, th thou by 20 degrees, and then you have your is, which means Iscar. Cylon grades 45, and if it has a C, it's going to be a coded insert.
So we have a massive line of edge preps, and if you're familiar with ceramics edge preps can make or break an operation to 2 degrees 4 degrees 24 thou 2,020 degrees 30 degrees makes a huge difference on chip, chip control.
So aerospace a lot of aerospace companies use ceramics. A lot of the components that are forged have a lot of material that has to come off running carbide. You could be taking multiple shifts to do what a ceramic can do in one shift.
Some of the typical parts. We'll see out that that will apply to ceramics - your fan casings, your low pressure compressors, combustion case, turbine casing, any heat, resistant super alloy like your ink canals, your wasp, boys, your Renes, your has alloys stuff like that.
So these are alloys, alloy groups anywhere from 33 to 35 depending on what we're looking at. Whisker, cylon bidemics those material groups, those high temp, those high temperature alloy groups are where ceramics can apply.
So Inconel 718 kind of like the industry baseline threshold for high temp alloys.
So Inconel 7, 18, at an operating temperature of 800°C is where that curve from carbide to ceramic hits. Once you hit that 800°C carbide drastically fails but ceramic will continue to hold strong. So ceramics maintain their flexoral strength at high temperatures. Once we get over that 800°C, it gets hot, there'll be some downward turn for the ceramic, but we're at operating temperatures. Now we want to see those chits popping off those parts.
So what we just seen from left to right, your carbide, your bidemics, your cylon, and your whisker your conventional carbide 7, 18, you know, depending on the type of machine, I understand. So it's 35 meters per second. So roughly, I mean, we're talking 35 times 3.3 point 3 105 Sfm. Roughly. We're not machining very fast. These are carbide operating temperatures depending on the carbide grade you're using bidemics cylons and your whiskers fly in high temperature alloys. I mean, we're talking 4 times the speed compared to carbide. Typically and that's just for your cylons or your whiskers. We throw in the bidemics. We're talking 6 times 7 times faster.
So, for example, right here, this is still metric. This is a metric conversion, but you're cutting speeds and turning. So 250 meters per minute compared to your carbide, you're 40. We're about 4 times faster. Chip metal removal rate with ceramics compared to carbide for milling.
We have this chart for milling. If milling, which will apply much more heat. So I do like to tell people to keep that in mind. There's a lot more heat being put into that part in milling, but 17 times faster. So if you have a milling application that you could potentially apply ceramics for a high temperature alloy, you can remove material 17 times faster than car button the automotive industry.
Your cast iron applications, ceramics work very well.
So Iscar offers an is 26, so the is 26 can be used both dry and wet, and you're turning the milling application and said numerically, depending on what we're doing, we have an in 18, which is for finishing. And then, if we're getting into roughing or scale or interrupted, cut, your is 45. So your is 26 is going to be your middle of the road in 18 smaller number, harder piece of ceramic, and then we have your is 45, coated and uncoated, which is going to be your tougher piece of ceramic.
So just an example. So 600 meters per minute. So 3 times 3, 6, 1218. So we're about, you know, 1,900 Sfm, roughly on your gray cast iron. So ceramic can get rid of material very quickly.
Ceramic is tough. Ceramic can be hard. Just depends on what we're doing. So now we're looking at a scaled information. Your cast iron, ductable cast iron. This is your is 45 C. So coated flying through.
So if you're using carbide for your cast irons right now, and you're roughing with it. We have ceramics that can be applied to your clean, continuous, or your roughing your scale your interrupted cut your micro stamps. We have ceramics that can do it.
An example of your operating ranges depending on what you're doing. It's just a little quick cheat sheet. This is information we have in our new catalog, but I like to just plug this stuff in. So customers, distributors, sales, salesmen can see your gray cast iron middle of the road for turning and milling. 27, so 2,800 Sfm. For your turning application for finishing 1,800 Sfm. Your ductable cast iron. We're talking about 1640, nice middle of the road and typically dry or wet.
The feed, rate or depth of cut are influenced by the geometry. So we're just keeping the Sfm. On there. Because if we have a you know a CNGA, or if we're using around, that'll influence your depth of cut and your feed rate.
So ceramic tools for hard turning. So you have your automotive, your steel industry, your mill roll stuff, your gear, your shaft gear, your crankshaft, and your bearing work. You know your ceramic for automotive.
So this car offers your in 16 said numerically. Your in 16 is going to be closer to the threshold, higher on the wear resistance close to CBN. So if we're in a situation where CBN and we might be on that threshold of, you know, 50, Rockwell, 55, Rockwell in 16 may be a potential solution. If we're trying to bridge that gap. CBN is not cheap if you're looking to be more cost effective, and it might not need a pristine 8, 8 finish. And it's, you know, maybe something like a 32, where we can get by with the ceramic in 16 could be a potential choice for clean, continuous cuts.
So something it could can take into consideration. So the advantages of ceramics you know this is, and this applies to all companies, your CBN, your ceramics, and your carbide price. CBN is much more costly than you have your ceramics and your carbide but something to keep in mind, as far as when am I going to apply which to which avenue so insert must be 3 times harder than the work material. That's why we have those thresholds of Hey 45, Rockwell for carbide anything above ceramics. So 45 to, you know, 55. That range for ceramics, and then anything above you have your 50 to and above for CBN. So things we take into consideration when we're looking at applications. We're not just going to plug in a CBN, because, hey, we got this CBN, that's going to go 1,600. Sfm, let's see what's more, cost effective. And let's see what makes sense for your application.
Because, hey, maybe we don't want to go 1,600 Sfm, maybe we can plug in a ceramic at 800 Sfm. And hit your 16 or 32 finish with a hard piece of ceramic, or we need that 8 finish.
We need to get these parts off the machine faster because the shop rates at a as at a certain rate. Where that CBN that rate the feed rates. We can go the Sfms. We can go balance everything out.
So stuff we take into consideration when we're looking at applications.
So that was a quick overview PCD CBN Ceramics. Great tools, application specific. We have your said, your non-ferrous for your PCD. That coal alloy group. Then we have your CBN and ceramics. We're going to be applied to cast iron, high temp alloys, hardened steel. If you have any questions or any applications we want, you want us to look at, please feel free to reach out to our sales team.
Jake Kauffman: Well, thank you so much, Robert, for that presentation, and we do have time for a few questions, and we were able to get a few in already from the audience. Kevin would like to know? So far, what mix of hard turning. Do you see with CBN is one pass versus 2 pass process.
Robert Navarrete: So the mixture will really depend on the geometry of the parts or the times. We, the instances we do see it. If it's like a larger diameter, low pressure turbine engine component when they have to do gauge passes. So it really depends on the part. CBNS are very consistent. They're very hard. So as long as you're within the depth of cut range you can typically take it in a single shot.
Jake Kauffman: Okay? And then Kevin also wants to know. Is there a tolerance or Cpk requirement that would steer you to use either one pass or 2 pass.
Robert Navarrete: Not necessarily, I said. CBNS, like in the Swiss world, stuff like that, I mean easily hit plus or plus or minus half a thou? I mean, that's a it's just an easy target.
Jake Kauffman: Awesome. Also, Robert looks like Danny wants to know how small of a corner radius can you make with the chip breaker the material that he's going to be using is platinum iridium.
Robert Navarrete: So off the shelf. It would be a 16th hour radius with the chip, former off the shelf. Let's see also what is the most ideal for a small diameter. Id boring on a thick walled 304 stainless steel at a point 0 0 5 tolerance.
So we didn't talk about it today, that would be, I would steer more towards Cermet for that application, not a CBN or a Suram that'd be a cermet application, in my opinion. A coated cermet
Jake Kauffman: Well, yeah, if there are any more questions. Obviously Robert is here to answer. But obviously it was a very informative presentation. So it looks like we do have. Oh, one more coming in. So we do have. Oh, no, Kevin, just saying, Thank you for your expertise as well. So obviously like I, said Robert, very informative presentation and I appreciate you taking the time today. Obviously, you were talking about your travel. So I definitely appreciate that you were able to sign on with us for a few questions. Thank you to the whole team at Iscar, and obviously a massive thank you to you, Robert. Thank you so much for your time today, and I hope you have a great rest of your day.
Robert Navarrete: All right. Thank you very much. Thank you for having me.
GIE Media transcripts are created quickly. This text may not be in its final form and may be updated or revised in the future. Accuracy and availability may vary. The authoritative record of GIE Media's webinar is the recording.
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