FS/LS MS/RS. The new high Al-rich (Al,Ti)N single layer coating significantly reduces edge fracturing.

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1 TOOL NEW IO Turning Inserts for Difficult-to-cut Materials Update B214G Item Expansion The new high Al-rich (Al,Ti)N single layer coating significantly reduces edge fracturing. MP9005 MP9015 MT9005 MT9015 F/L M/R A

2 IO Turning Inserts for Difficult-to-cut Materials PVD Coated Grade MP9005/MP9015 High Al-rich (Al,Ti)N ingle Layer Coating Technology pecial Cemented Carbide ubstrate MP9005/MP9015 High Al and Conventional Coating Comparison The new technology high Al-rich (Al,Ti)N single layer coating provides stabilization of the high hardness phase and succeeds in dramatically improving wear, crater and welding resistance. New Technology oft Phase High Hardness Phase Hardness of Coating (HV) Conventional Technology High Al-rich (Al,Ti)N ubstrate ubstrate Al Content (at%) IO Grade Grade Concept Application Heat Resistant Alloys 01 MP9005 Top-quality grade focusing on wear resistance. Finish- Heat Resistant Alloys 10 MP9015 First recommendation for general applications. Medium-Rough Cutting Carbide Grade (Non Coated) MT9005/MT9015 Application Range IO PVD Cemented Carbide Heat Resistant Alloys Ti Alloys MP9005 MP9015 MT9005 MT9015 MT9005 MT IO Grade Grade Concept Application New cemented carbide with unmatched Titanium Alloys 01 MT9005 resistance to heat and plastic deformation. High peed Cutting New cemented carbide with sharp cutting edge, Titanium Alloys 10 MT9015 excellent wear and fracture resistance.

3 New Chip Breaker ystem Negative Inserts LBreaker for Light Cutting Enhanced chip disposal for depths of cut smaller than the corner R. Nose mm Flank mm 4.0 Chip Control Range R MBreaker Newly Designed for The large 2-step rake angle generates chips smoothly and without tangling during low feed cutting. Nose Flank 0.5 mm 0.5 mm Depth of Cut ap M RBreaker for Rough Cutting During low speed cutting the positive land controls chip welding and abrasion at the depth of cut line. Nose 0.2 mm Flank 0.2 mm L Feed per Revolution f (mm/rev) The chip breaker control range was tested for optimum chip evacuation when cutting Inconel718 with a CNMG120408oo insert. 0.4 MABreaker Multi-assist Breaker uitable for medium cutting range mm MJBreaker ub Breaker Alternative chip breaker of main chip breaker L and M. Excellent notch wear resistance for light to medium cutting. Positive Inserts LBreaker for Light Cutting Prevents welding of the insert and controls white turbidity of the surface fi nish. Nose 6 Nose Nose 18 8 MBreaker for Flank 0.2 mm 22 6 Flank 9 Flank Depth of Cut ap Depth of Cut ap MJ L Chip Control Range MA Feed per Revolution f (mm/rev) Chip Control Range M 0.4 A wide chip pocket controls increasing of the cutting resistance and reduces vibration and chip jamming even at large depth of cut. Nose mm Flank 0.1 mm Feed per Revolution f (mm/rev) 0.4 The chip breaker control range was tested for optimum chip evacuation when cutting Inconel718 with a DCMT11T304oo insert. 2

4 New Precision Chip Breaker ystem Positive Inserts F/F-P Breaker for Finish Cutting F First Recommendation for Finish Cutting of Difficult-to-cut Materials Ideal for heat resistant alloys, titanium alloys, and cobalt chromium alloys. harp cutting edges provide excellent surface precision and fi nish. Highly effi cient chip discharge is possible due to curved cutting edges Nose Flank F-P Mirror Finish First Recommendation for Finish Cutting of Titanium Alloys Ideal for titanium alloys and copper alloys. harp cutting edges provide excellent surface precision. Highly effi cient chip discharge is possible due to curved cutting edges. Polished (mirror-surface) fi nish of insert surfaces drastically improves welding resistance extending tool life. L/L-P Breaker for Light Cutting Depth of Cut ap Chip Control Range L/L-P F/F-P L First Recommendation for Light Cutting of Difficult-to-cut Materials Ideal for heat resistant alloys, titanium alloys, and cobalt chromium alloys. Designed with parallel cutting edges. Achieves stable chip control over a wide range from low to medium depths of cut Feed per Revolution f (mm/rev) L-P First Recommendation for Light Cutting of 12 Titanium Alloys Mirror Finish Ideal for titanium alloys and copper alloys. Designed with parallel cutting edges. Achieves stable chip control over a wide range from low to medium depths of cut. 6 Polished (mirror-surface) fi nish of insert surfaces drastically improves welding resistance extending tool life. Nose Flank 3

5 Negative Inserts (With Hole) M Class Light Medium Medium L M MA CNMG Medium Rough MJ R EPR 80º Order Number Cutting Area MP9005 MP9015 MT9015 CNMG L L a a CNMG L L a a CNMG L L a a a CNMG L L a a a CNMG L L a a a CNMG M M a a CNMG M M a a CNMG M M a a a CNMG M M a a a CNMG M M a a a CNMG M M a a a CNMG M M a a a CNMG MA M a CNMG MA M a CNMG MA M a CNMG MA M a CNMG MJ M a a CNMG MJ M a a CNMG MJ M a a CNMG MJ M a a CNMG R R a a CNMG R R a a CNMG R R a a CNMG R R a a CNMG R R a a CNMG R R a a CNMG R R a a a : Inventory maintained in Japan. 4

6 IO Turning Inserts for Difficult-to-cut Materials Negative Inserts (With Hole) Light Medium Medium M Class L M MA DNMG Medium Rough MJ R EPR 55º Order Number Cutting Area MP9005 MP9015 MT9015 DNMG L L a a a DNMG L L a a a DNMG L L a a a DNMG L L a a a DNMG L L a a a DNMG M M a a a DNMG M M a a a DNMG M M a a a DNMG M M a a a DNMG M M a a a DNMG M M a a a DNMG MA M a DNMG MA M a DNMG MA M a DNMG MA M a DNMG MA M a DNMG MA M a DNMG MJ M a a DNMG MJ M a a DNMG MJ M a a DNMG MJ M a a DNMG MJ M a a DNMG MJ M a a DNMG MJ M a a DNMG MJ M a a DNMG R R a a DNMG R R a a DNMG R R a a DNMG R R a a DNMG R R a a DNMG R R a a a : Inventory maintained in Japan.

7 Negative Inserts (With Hole) M Class Medium Medium Rough NMG M MA R EPR 90º Light Medium Medium Medium Rough TNMG L M MA MJ R EPR 60º Order Number Cutting Area MP9005 MP9015 MT9015 NMG M M a a a NMG M M a a a NMG M M a a a NMG M M a a a NMG M M a a a NMG M M a a NMG MA M a NMG MA M a NMG MA M a NMG MA M a NMG R R a a NMG R R a a NMG R R a a NMG R R a a NMG R R a NMG R R a a TNMG L L a a a TNMG L L a a a TNMG L L a a a TNMG M M a a a TNMG M M a a a TNMG M M a a a TNMG M M a a a TNMG M M a a a TNMG MA M a TNMG MA M a TNMG MA M a TNMG MA M a TNMG MA M a TNMG MA M a TNMG MA M a TNMG MA M a TNMG MJ M a a TNMG MJ M a a TNMG MJ M a a TNMG R R a a TNMG R R a a TNMG R R a a TNMG R R a a

8 IO Turning Inserts for Difficult-to-cut Materials Negative Inserts (With Hole) Light Medium Medium M Class VNMG L M MJ EPR 35º Light Medium Medium Medium Rough WNMG EPR 80º L M MA MJ R Order Number Cutting Area MP9005 MP9015 MT9015 VNMG L L a a a VNMG L L a a a VNMG L L a a a VNMG M M a a a VNMG M M a a a VNMG MJ M a a VNMG MJ M a a VNMG MJ M a a WNMG L L a a a WNMG L L a a a WNMG L L a a a WNMG M M a a a WNMG M M a a a WNMG M M a a a WNMG MA M a WNMG MA M a WNMG MA M a WNMG MA M a WNMG MJ M a a WNMG MJ M a a WNMG MJ M a a WNMG R R a a WNMG R R a a WNMG R R a a WNMG R R a a a : Inventory maintained in Japan.

9 7 Positive Inserts (With Hole) M Class Light Medium DCMT L M CCMT EPR 55º AN 7 Light Medium Medium EPR 80º AN 7 CMT EPR 90º AN 7 L M M Order Number Cutting Area MP9005 MP9015 MT9005 CCMT L L a a a CCMT L L a a a CCMT09T302-L L a a a CCMT09T304-L L a a a CCMT09T308-L L a a a CCMT M M a a a CCMT M M a a a CCMT M M a a a CCMT09T302-M M a a CCMT09T304-M M a a a CCMT09T308-M M a a a CCMT M M a a a CCMT M M a a a CCMT M M a a a DCMT L L a a a DCMT L L a a a DCMT11T302-L L a a a DCMT11T304-L L a a a DCMT11T308-L L a a a DCMT M M a a a DCMT M M a a a DCMT11T304-M M a a a DCMT11T308-M M a a a DCMT11T312-M M a a a CMT09T304-M M a a a CMT09T308-M M a a a CMT M M a a a CMT M M a a a CMT M M a a a

10 IO Turning Inserts for Difficult-to-cut Materials 5 and 7 Positive Inserts (With Hole) M Class Light Medium VBMT L M TCMT EPR 35º AN 5 Light Medium Light Medium EPR 60º AN 7 VCMT EPR 35º AN 7 L M L M Order Number Cutting Area MP9005 MP9015 MT9005 TCMT L L a a a TCMT L L a a a TCMT M M a a a TCMT M M a a a TCMT M M a a TCMT M M a a TCMT16T304-M M a a a TCMT16T308-M M a a a TCMT16T312-M M a a a VBMT L L a a a VBMT L L a a a VBMT L L a a a VBMT L L a a a VBMT L L a a a VBMT M M a a a VBMT M M a a a VBMT M M a a a VBMT M M a a a VCMT L L a a a VCMT L L a a a VCMT L L a a a VCMT L L a a a VCMT M M a a VCMT M M a a a VCMT M M a a a VCMT M M a a a VCMT M M a a a a : Inventory maintained in Japan.

11 7 Positive Inserts (With Hole) G Class CCGT Finish Finish Light Light F F-P L L-P EPR 80º DCGT AN 7 Finish Finish Light Light F F-P L L-P EPR 55º AN 7 Order Number Cutting Area MP9005 MP9015 MT9005 CCGT060201M-F F a a CCGT060202M-F F a a CCGT09T301M-F F a a CCGT09T302M-F F a a CCGT09T304M-F F a a CCGT060201M-F-P F a CCGT060202M-F-P F a CCGT09T301M-F-P F a CCGT09T302M-F-P F a CCGT09T304M-F-P F a CCGT060201M-L L a a CCGT060202M-L L a a CCGT09T301M-L L a a CCGT09T302M-L L a a CCGT09T304M-L L a a CCGT060201M-L-P L a CCGT060202M-L-P L a CCGT09T301M-L-P L a CCGT09T302M-L-P L a CCGT09T304M-L-P L a DCGT070201M-F F a a DCGT070202M-F F a a DCGT11T301M-F F a a DCGT11T302M-F F a a DCGT070201M-F-P F a DCGT070202M-F-P F a DCGT11T301M-F-P F a DCGT11T302M-F-P F a DCGT070201M-L L a a DCGT070202M-L L a a DCGT070204M-L L a a DCGT11T301M-L L a a DCGT11T302M-L L a a DCGT11T304M-L L a a DCGT070201M-L-P L a DCGT070202M-L-P L a DCGT070204M-L-P L a DCGT11T301M-L-P L a DCGT11T302M-L-P L a DCGT11T304M-L-P L a

12 IO Turning Inserts for Difficult-to-cut Materials 7 Positive Inserts (With Hole) G Class L Light VCGT Light EPR 35º AN 7 L-P Order Number Cutting Area MP9005 MP9015 MT9005 VCGT110301M-L L a a VCGT110302M-L L a a VCGT110304M-L L a a VCGT130301M-L L a a VCGT130302M-L L a a VCGT130304M-L L a a VCGT110301M-L-P L a VCGT110302M-L-P L a VCGT110304M-L-P L a VCGT130301M-L-P L a VCGT130302M-L-P L a VCGT130304M-L-P L a a : Inventory maintained in Japan.

13 Recommended Cutting Conditions y Negative Inserts Work Material Cutting Conditions Cutting Area M Light Cutting L MP Precipitation Hardening tainless teels (AII 630) M MP R MP L MP M MP R MP Light Cutting L MT Titanium Alloys (Ti-6Al-4V) Ni Based Heat Resistant Alloys (Inconel718, Hastelloy, WAPALOY) Co Based Heat Resistant Alloys (Tribaloy, tellite) table Cutting table Cutting table Cutting Rough Cutting Light Cutting Rough Cutting Rough Cutting Light Cutting Rough Cutting Light Cutting Rough Cutting Light Cutting Rough Cutting Chip Breaker Grade vc (m/min) f (mm/rev) M MT R MT L MT M MT R MT L MP M MP R MP L MP M MP R MP (Note 1) When cutting conditions are unstable, please refer to page 2 for recommended chip breaker and grade. (Note 2) Verify the recommended conditions for each boring bar as cutting conditions for internal machining will vary depending on the length of overhang. ap y Positive Inserts Work Material Cutting Conditions Cutting Area Chip Breaker M Light Cutting L MP table Cutting Precipitation Hardening tainless teels M MP (AII 630) Light Cutting L MP M MP Finish and Light L MT table Cutting M MT Grade vc (m/min) f (mm/rev) ap Titanium Alloys (Ti-6Al-4V) Finish and Light L MT M MT Unstable Cutting Finish and Light L MT M MT table Cutting Finish and Light L MP M MP Ni Based Heat Resistant Alloys (Inconel718, Hastelloy, WAPALOY) Finish and Light L MP M MP Unstable Cutting Finish and Light L MP M MP vc = Cutting peed ap = Depth of Cut f = Feed per Revolution 12

14 IO Turning Inserts for Difficult-to-cut Materials Recommended Cutting Conditions y Precision Positive Inserts Work Material vc (m/min) f (mm/rev) M F MP table Cutting L MP Precipitation Hardening tainless teels F MP (AII 630) L MP L MP F-P MT table Cutting L-P MT Titanium Alloys F-P MT (Ti-6Al-4V) L-P MT Cobalt Chromium Alloys (Co-Cr-Mo Alloy) Ni Based Heat Resistant Alloys (Inconel718, Hastelloy, WAPALOY) Cutting Conditions Unstable Cutting Unstable Cutting table Cutting Unstable Cutting table Cutting Unstable Cutting Chip Breaker Grade F-P MT F MP L MP F MP L MP L MP F MP L MP F MP L MP F MP ap vc = Cutting peed ap = Depth of Cut f = Feed per Revolution y For Effective Use of Large Corner Radius By setting the depth of cut smaller than the corner radius value, notching during cutting of heat resistant alloys can be greatly reduced. Corner Radius > 1.5 x Depth of Cut Depth of cut : 0.6mm. Corner radius over 0.9mm is recommended. Point A smaller lead angle is the key to reduced notching. Lead Angle (Large) 0.6 mm 0.6 mm R 0.8 mm Lead Angle (mall) R 1.2 mm 13

15 Cutting Performance Comparison in Continuous Machining of Precipitation Hardening tainless teels AII Conventional B Cutting Time : 48min (Wear Photo) Flank Wear Width Max MP9015 M Breaker Conventional A MP9015 M Breaker Conventional A Cutting Time (min.) <Cutting Conditions> Work Material : AII 630 Inserts : CNMG oo Conventional B Machining Methods : External Continuous Cutting Cutting peed : vc=120 m/min Feed per Rev. : f=0.2 mm/rev Depth of Cut : ap=1.5 mm Cutting Mode : Wet Cutting Achieved double tool life when machining Inconel718 during continuous machining MP9005+L Conventional A (10) Conventional B (10) Conventional C (10) Wear mm Wear mm Wear mm Wear mm Cutting Time 66 min Cutting Time 22 min Cutting Time 36 min Cutting Time 16 min <Cutting Conditions> Work Material : Inconel718 Inserts : CNMG oo Cutting peed : vc=50 m/min Feed per Rev. : f=0.15 mm/rev Depth of Cut : ap=0.5 mm Cutting Mode : Wet Cutting Comparison of Wear Resistance by Work Material Materials and Cutting Conditions New Chip Breaker Conventional A Conventional B Work Material : Co-Cr-Mo Alloy Inserts : DCGT11T304M-L Grade : MP9005 Cutting peed : vc=40 m/min Feed per Rev. : f=0.05 mm/rev Depth of Cut : ap=0.2 mm Cutting Mode : Wet Cutting (Water-soluble) Machine : CNC Automatic Lathes Cutting Time : 12 min. Work Material : Inconel718 Inserts : DCGT11T304M-L Grade : MP9015 Cutting peed : vc=60 m/min Feed per Rev. : f=0.05 mm/rev Depth of Cut : ap=0.5 mm Cutting Mode : Wet Cutting (Water-soluble) Machine : CNC Automatic Lathes Cutting Time : 20 min. Work Material : Ti-6Al-4V ELI Inserts : DCGT11T304M-L-P Grade : MT9005 Cutting peed : vc=80 m/min Feed per Rev. : f=0.05 mm/rev Depth of Cut : ap=3.0 mm Cutting Mode : Wet Cutting (Water-insoluble) Machine : Automatic Lathes 35 Pieces (Non-coat) 35 Pieces (PVD) 15 Pieces (PVD) 14

16 IO Turning Inserts for Difficult-to-cut Materials Flank Wear Width Max. Cutting Performance Inconel718, vc=60 m/min Continuous Machining Conventional A 4 Conventional B 8 12 Conventional C Cutting Time (min.) MP9015 M Breaker <Cutting Conditions> Work Material : Inconel718 Insert : CNMG oo Cutting peed : vc=60 m/min Feed per Rev. : f=0.15 mm/rev Depth of Cut : ap=0.75 mm Cutting Mode : Wet Cutting Increased 28 % Tool Life Conventional A 8 min 1 2 Conventional A 4 min 3 Conventional B 12 min 4 Conventional B 6 min Cutting Time (min.) Conventional C 26 min 8 Conventional C 8 min 32 9 MP9015 M Breaker 34 min Inconel718, vc=100 m/min Continuous Machining Flank Wear Width Max. Flank Wear Width Max. Conventional A Conventional B Conventional C Inconel718, ap=2.0 mm Continuous Machining Conventional A Conventional B Conventional C Cutting Time (min.) MP9005 M Breaker MP9005 M Breaker 11 min MP9015 R Breaker 44 <Cutting Conditions> Work Material : Inconel718 Insert : CNMG oo Cutting peed : vc=100 m/min Feed per Rev. : f=0.15 mm/rev Depth of Cut : ap=0.5 mm Cutting Mode : Wet Cutting Increased 37 % Tool Life <Cutting Conditions> Work Material : Inconel718 Insert : CNMG oo Cutting peed : vc=40 m/min Feed per Rev. : f=0.2 mm/rev Depth of Cut : ap=2.0 mm Cutting Mode : Wet Cutting Conventional A 8 min Conventional B 18 min Conventional C 32 min WAPALOY Continuous Machining MP9015 with R breaker was smallest damage. MP9015 R Breaker 40 min Increased 33 % Tool Life 15 Conventional A Conventional B MP9015 R Breaker <Cutting Conditions> Work Material : WAPALOY Insert : CNMG oo Cutting peed : vc=29 m/min Feed per Rev. : f=0.22 mm/rev Depth of Cut : ap=4.0 mm Cutting Time : 7 min Cutting Mode : Wet Cutting

17 Titanium Alloy, Comparison of urface Finish (Depth of Cut : 0.25 mm) (μm) mm Ra : μm Rz : μm Rzjis : μm (μm) mm Ra : μm Rz : μm Rzjis : μm Glossy urface 5 mm MT9015 L Breaker White Turbidity 5 mm Conventional Excellent Finish <Cutting Conditions> Work Material : Ti-6Al-6V(325HB) Insert : CNMG oo Cutting peed : vc=70 m/min Feed per Rev. : f=0.05 mm/rev Depth of Cut : ap=0.25 mm Cutting Mode : Wet Cutting MP9015 with L breaker was smallest damage. Conventional MP9015 L Breaker <Cutting Conditions> Work Material : Heat Resistant Cast teel Insert : DCMT11T304-oo Cutting peed : vc=100 m/min Feed per Rev. : f=0.1 mm/rev Depth of Cut : ap=0.25 mm Cutting Mode : Wet Cutting Chip Control when Back Turning Non-tangling of chips when back turning Inconel718. M Breaker New Design Conventional 45 <Cutting Conditions> Work Material : Inconel718 Insert : DNMG oo Cutting peed : vc=40 m/min Feed per Rev. : f=0.2 mm/rev Depth of Cut : ap=1.0 mm Cutting Mode : Wet Cutting 16

18 IO Turning Inserts for Difficult-to-cut Materials Cutting Conditions Application Examples Insert (Grade) DCGT11T304M-L (MP9015) DCGT11T302M-L (MP9015) Workpiece AII 430 Forgings AII 630 (17-4PH) Cutting peed vc (m/min) Feed per Rev. f (mm/rev) Depth of Cut ap Cutting Mode Wet Cutting (Water-insoluble Coolants) Wet Cutting (Water-insoluble Coolants) Machine CNC Automatic Lathes CNC Automatic Lathes Results Compared to conventional products with inconsistent tool life, whose unstable chip evacuation can cause entanglement of chips in workpieces, the L breaker provided stable chip evacuation allowing machining to be performed up to machining constants. It also exhibited excellent wear conditions after turning. Even when machining at 1.5 times the machining constants of conventional products, there were no variations in turning surface dimensions. The amount of wear was also extremely small, making machining extension and cost reduction possible. Cutting Conditions Insert (Grade) DCGT11T302M-F-P (MT9005) DCGT070201M-F (MP9015) Workpiece Cutting peed vc (m/min) Ti-6AI-4V ELI 65 AII Feed per Rev. f (mm/rev) Depth of Cut ap Cutting Mode Wet Cutting (Water-insoluble Coolants) Wet Cutting (Water-insoluble Coolants) Machine CNC Automatic Lathes CNC Automatic Lathes Results Compared to conventional PVD coated products, the cemented carbide MT 9005 (uncoated) provided exceptional machined surface roughness even at double the number of cuts. The extremely small amount of wear and stable dimensional precision allowed further machining extension. Compared to conventional products, the amount of wear was small and chip evacuation was excellent, making it possible to perform machining at 1.5 times the machining constant. Insert (Grade) DNMG M (MP9005) Inconel718 (Ni Based Heat Resistant Alloy) ø240 mm CNMG R (MP9015) HAYNE Alloy 25 (Co Based Heat Resistant Alloy) Workpiece ø42 mm 45HRC Aging Treatment Component Disk - Aerospace Component Cover Plate - Aerospace Component Application Internal Turning External Turning Cutting Conditions Cutting peed vc (m/min) Feed per Rev. f (mm/rev) Depth of Cut ap ae (3 Pass) Cutting Mode Wet Cutting Wet Cutting Conventional (10) MP9005+M Conventional (10) MP9015+R Results MP table machining and less wear with long tool life without chip tangling. Both conventional and MP9015 display notch wear but the conventional grade wear was greater and exposed the substrate. 17

19 Memo 18

20 MP9005/MP9015 MT9005/MT9015 IO Turning Inserts for Diffi cult-to cut Materials MP9005/MP9015 MT9005/MT9015 For Your afety adon't handle inserts and chips without gloves. aplease machine within the recommended application range and exchange expired tools with new ones in advance of breakage. aplease use safety covers and wear safety glasses. awhen using compounded cutting oils, please take fire precautions. awhen attaching inserts or spare parts, please use only the correct wrench or driver. awhen using rotating tools, please make a trial run to check run-out, vibration and abnormal sounds etc. MITUBIHI MATERIAL CORPORATION Overseas ales Dept, Asian Region KFC bldg., 8F, Yokoami, umida-ku, Tokyo , Japan TEL FAX Overseas ales Dept, European & American Region KFC bldg., 8F, Yokoami, umida-ku, Tokyo , Japan TEL FAX (Tools specifications subject to change without notice.) EXP-13-E ( - )