Metallurgy and Machinability

Metallurgy Overview Machinability Overview

Cast irons are iron-carbon-silicon alloys containing Machinability refers to the ease with which a
large amounts of carbon either as graphite or as workpiece can be machined and measured in
iron carbide. They have higher carbon (>1.7%) terms of tool life, metal removal rates, surface
and silicon (1.0-3.5%) contents than steel. Silicon finish, ease of chip formation, or cutting forces.
promotes dissociation of iron carbide to iron and It is not an intrinsic property of a material, but
graphite. By increasing the silicon content in cast is a result of complex interactions between the
iron, a greater proportion of graphite can be mechanical properties of the workpiece, cutting
obtained at the expense of combined carbon. tools, lubricants used, and machining conditions.
The microstructure and mechanical properties of Cast iron machinability varies greatly depending on
cast irons can be controlled not only by chemical the type of iron and its microstructure. Ferritic cast
composition but also by cooling rate. Increasing the irons are easiest to machine, while white irons are
cooling rate will refine the graphite size as well as extremely difficult to machine. Other grades of
the matrix structure and will increase strength and cast iron, such as malleable, ductile, compacted
hardness. It also may increase the chilling graphite, and alloyed cast irons, are in between fer-
tendency, which may increase the hardness but ritic and white irons in ease of machinability.
decrease the strength. Additionally, hard spots in castings formed
Alloys within the broad group of cast irons include during rapid cooling and in presence of excessive
white iron, gray cast iron, mottled cast iron, levels of carbide forming elements can seriously
malleable cast iron, and ductile cast iron. Each degrade machinability.
of these alloys may be modified by alloy additions Alloy cast irons (ASTM A532, A518) can be
to obtain specific properties. Below are selected classified as white cast irons, corrosion-resistant
ASTM standards for different classes of cast irons. irons, and heat-resistant irons. Generally, they are
Selected ASTM Standards for Cast Irons based on the iron (Fe) - carbon (C) - silicon (Si)
system and contain one or more alloying elements
Unalloyed Cast Irons
that are added (>3%) to enhance one or more
A47 Malleable iron castings
useful properties (corrosion resistance or strength
A48 Gray iron castings
A126 Gray iron castings for valves, flanges, or oxidation resistance at elevated temperatures).
and pipe fittings Small amounts of ferrosilicon, cerium, or
A159 Automotive gray iron castings magnesium that are added to control the size,
A197 Cupola malleable iron shape, and distribution of graphite particles are
A220 Pearlitic malleable iron castings
called inoculants, rather than alloying elements.
A278 Gray iron castings for pressure-containment
with temperatures up to 345° C (650° F) Inoculation does not change the basic composition
A319 Gray iron castings for elevated temperatures – or alter the properties of the constituents in the
non-pressure containing parts microstructure. The alloyed irons for corrosion
A395 Ferritic ductile iron pressure-retaining castings resistance are either 13-36% nickel (Ni) gray and
for elevated temperatures
A476 Ductile iron castings for papermill dryer rolls
ductile irons (also called Ni-resist irons) or high
A536 Ductile iron castings silicon (~14.5% Si) gray irons. For elevated
A602 Automotive malleable iron castings temperature service, nickel (Ni), silicon (Si),
Low and Moderate Alloyed Cast Irons or aluminum (Al) alloyed gray and ductile irons
are employed.
A319 Gray iron castins for elevated temperatures for
non-pressure – containing parts
A874 Ferritic ductile iron castings for low-temperature
service parts
High-Silicon Cast Irons
A532 Abrasion-resistant cast irons
High-Nickel Austenitic Cast Irons
A436 Austenitic gray iron castings
A439 Austenitic ductile iron castings
571 Austenitic ductile iron castings for pressure-
containing parts for low-temperature service
32 Figure 1: Microstructure of white cast iron
Metallurgy and Machinability

White cast irons, also known as abrasion-resistant minimum tensile strength to class 60 with 60 ksi
cast irons, are an iron-carbon alloy in which the car- minimum tensile strength). The fluidity of liquid gray
bon content exceeds 1.7%. White cast iron does iron and its expansion during solidification due to
not have any graphite in the microstructure. the formation of graphite are responsible
Instead, the carbon is present either as iron- for the economic production of shrinkage-free,
carbide or complex iron-chromium carbides intricate castings such as engine blocks. Most gray
(Figure 1), which are responsible for high hardness iron components are used in the as-cast condition.
and resistance to abrasive wear. White iron shows However, for specific casting requirements, they
a white, crystalline fracture surface because can be heat treated (annealed, stress relieved,
fracture occurs along the carbide plates. White iron or normalized). Other heat treatments include hard-
can be produced either throughout the section or ening and tempering, austempering,
only on the surface by casting the molten metal martempering, and flame or induction hardening.
against graphite or metal chill. In the latter case,
it is referred to as chilled iron.
Corrosion-resistant cast irons obtain their
resistance to chemical wear primarily from their
high alloy content of silicon, chromium, or nickel.
Depending on which of the three alloys dominates
the compositions, the corrosion-resistant material Figure 2a: Type C flake Figure 2b: Pearlite-ferrite
can be ferritic, pearlitic, martensitic, or austenitic. graphite in gray iron gray cast iron

Machinability – Alloy Cast Irons

White irons and corrosion-resistant high-silicon
(14.5%Si) gray irons are the most difficult cast irons
to machine. Alloyed white irons such as nickel-hard
(Ni-hard) alloys and high-silicon irons (ASTM A518)
are generally ground to size or turned with a
polycrystalline cubic boron nitride (PCBN) tool Figure 2c: Coarse pearlite in Figure 2d: Pearlitic gray
gray cast iron cast iron
material such as Kennametal grades KB9640,
KD120, or KB5625 Machinability – Gray Cast Irons
Gray cast irons (ASTM A48, A126, A159, ASME Most gray cast irons are easier to machine than
AS278 and SAE J431) are named such because other cast irons of similar hardness and virtually
their fracture has a gray appearance and consists all steels. This is because the graphite flakes in the
of graphite flakes embedded in a matrix of ferrite or microstructure act as chip breakers and serve as
pearlite, or a mixture of the two depending on the a lubricant for the cutting tool. Machining difficulties
composition and cooling rate (Figures 2a-2d). can still occur in gray iron if chills are present
Ferrite is a soft, low-carbon alpha iron phase with in corners and thin sections or when sand is
low tensile strength but high ductility. Pearlite con- embedded in the casting surface. The material
sists of lamellar plates of soft ferrite and hard also shows a tendency to break out during exit
cementite. Gray irons contain 2.5 to 4% carbon (C), from the cut. Although the graphite in cast iron
1-3% silicon (Si), and manganese (Mn) (~0.1% Mn imparts its free-machining characteristics, the
in ferritic gray irons and as high as 1.2% Mn in matrix surrounding the graphite determines tool
pearlitic gray irons). Sulfur (S) and phosphorus (P) life. In fully annealed state, cast irons have a
may be present as residual impurities. Manganese ferritic matrix and exhibit the best machinability.
is deliberately added to neutralize the sulfur. The (While not as soft as ferrite in steel, the ferritic cast
resulting manganese sulfide is uniformly distributed iron shows better machinability than ferritic steel
in the matrix of gray iron as inclusions. due to the slight hardening effect of the dissolved
ASTM specification A48 classifies gray cast irons silicon and the chip breaking and lubricating effect
in terms of tensile strength (class 20 with 20 ksi of the graphite.) As the ferrite content decreases
Photomicrographs courtesy of Buehler Ltd., Lake Bluff, Illinois, USA, www.buehler.com
33
Metallurgy and Machinability

and pearlite increases, tool life decreases rapidly. iron before casting. The nodules act as crack
Both iron and alloy carbides, when present as arresters and impart ductility to the material. By
large particles, are detrimental to tool life. Irons contrast, neither white iron nor gray iron shows a
with higher phosphorous contents (~0.4%) form significant amount of ductility. Ductile iron is of
a hard constituent called steadite, which has a higher purity (low phosphorus [P] and sulfur [S])
detrimental effect on tool life. and is stronger than gray iron.
Gray cast irons are productively turned and milled With a high percentage of graphite nodules
with multi-layered alumina and TiCN coated present in the microstructure, the matrix
inserts. The substrate tool material can be either determines the mechanical properties of ductile
carbide or silicon nitride-based ceramic. Cermet iron. Table B compares the composition of ductile
grades such as KT315 are ideal for light depth-of- iron with that of gray iron and malleable iron.
cut applications. A pure silicon nitride grade such The ASTM classifies different grades of ductile
as KY3500 often yields the highest productivity irons in terms of tensile strength in ksi, yield
on general turning and milling applications at high strength in ksi, and elongation in percent. For
speeds. Drilling applications are highly dependent example, ASTM A536 specifies five standard
on the drill geometry as well as drill grade. ductile iron grades: 60-40-18 / 65-45-12 (ferritic
Kennametal solid carbide drills in the TF (triple ductile iron), 80-55-06 (ferritic-pearlitic ductile iron),
flute) and SE (sculptured edge) geometries in 100-70-03 (pearlitic ductile iron), and 120-90-02
TiALN-coated grades KC7210 and KC7215 are (quenched and tempered martensitic ductile iron).
the most desirable. For indexable insert drilling
Ferritic ductile iron — the ferrite matrix provides
applications, TiALN-coated KC7725 and alumina
good ductility and impact resistance and tensile
coated KC7935 grades are the first choice for
strength equivalent to low-carbon steel. Ferritic
high-speed, high productivity applications.
ductile iron can be produced “as-cast” or may be
Ductile (nodular) irons (ASTM A395, A476, given an annealing treatment to obtain maximum
A439, A536 and SAE J434), previously known ductility and low-temperature toughness.
as nodular iron or spheroidal-graphite cast iron,
Ferritic-pearlitic ductile irons — usually
contain nodules of graphite embedded in a matrix
produced in the “as cast” condition and feature
of ferrite or pearlite or both (Figures 3a-3c). The
both ferrite and pearlite in the microstructure.
graphite separates as nodules from molten iron
Properties are intermediate between ferritic
during solidification because of additives cerium
and pearlitic ductile irons.
(Ce) and magnesium (Mg) introduced in the molten

Figure 3a: Ferritic annealed ductile iron Figure 3b: Pearlite/ferrite ductile iron Figure 3c: Coarse lamellar pearlite in
ductile iron
Table B – Typical composition ranges for unalloyed cast irons
composition %
total silicon chromium nickel molybdenum copper phosphorus sulfur cerium magnesium
material manganese
carbon (Si) (Cr) (Ni) (Mo) (Cu) (P) (S) (Ce) (Mg)
gray
iron 3.25-3.50 0.50-0.90 1.80-2.30 0.05-0.45 0.05-0.20 0.05-0.10 0.15-0.40 0.12 max 0.15 max ... ...
malleable
iron 2.45-2.55 0.35-0.55 1.40-1.50 0.04-0.07 0.05-0.30 0.03-0.10 0.03-0.40 0.03 max 0.05-0.07 ... ...
ductile
iron 3.60-3.80 0.15-1.00 1.80-2.80 0.03-0.07 0.05-0.20 0.01-0.10 0.15-1.00 0.03 max 0.002 max 0.005-0.20 0.03-0.06

34
Metallurgy and Machinability

Pearlitic ductile irons - the pearlitic matrix shaped graphite nodules (often called “temper
provides high strength, good wear resistance, graphite” because it is formed by the dissolution
and moderate ductility and impact resistance. of cementite in the solid state) embedded in a
While the aforementioned three types of ductile iron matrix of ferrite, pearlite (Figure 4), or tempered
are most common and used in as-cast condition, martensite. Malleable iron is cast as white iron
ductile irons also can be alloyed and/or heat- and then heat-treated to impart ductility to an
treated to provide additional grades as follows: otherwise brittle material. Malleable iron possesses
considerable ductility and toughness due to the
Martensitic ductile irons are produced using
nodular graphite and a lower carbon metallic
sufficient alloy additions to prevent pearlite
matrix. It has good fatigue strength and damping
formation, and a quench-and-temper heat treatment
capacity, good corrosion resistance, good magnetic
to produce a tempered martensitic matrix. These
permeability, and low magnetic retention for
materials have a high strength and wear resistance
magnetic clutches and brakes. Malleable iron, like
but lower levels of ductility and toughness. Bainitic
medium-carbon steel, can be heat treated to obtain
ductile irons are produced through alloying and/or
different matrix microstructures (ferrite, pearlite,
by heat treatment to provide a hard, wear-resistant
tempered pearlite, bainite, tempered martensite, or
material. Austenitic ductile irons are produced
a combination of these) and mechanical properties.
through alloying additions to provide good corrosion
and oxidation resistance, magnetic properties, Malleable and gray irons differ in two respects: the
and strength and dimensional stability at iron carbide is partially or completely dissociated
high temperatures. in malleable cast iron; the dissociation occurs only
when the alloy is solid. However, the dissociation in
Machinability - Ductile Irons
gray cast iron occurs during the early stages of
The spherical graphite in ductile iron acts similar to solidification; hence the difference in the character
the flake graphite in gray iron in chip breaking and of graphite in each material.
lubrication in machining. Machinability increases
with silicon content up to 3%, but decreases
significantly at higher silicon levels. As in the case
of gray cast iron, machinability decreases with
increasing pearlite content in the microstructure.
Finer pearlite structures also decrease machinabili-
ty. Still, pearlitic ductile irons are considered to have
the best combination of machinability and wear
resistance. Cast irons with tempered martensitic
structure have a better machinability than pearlite
with similar hardness. Other microstructures such
as acicular bainite and acicular ferrite formed
during heat treatment of ductile irons have
machinability similar to martensite tempered to
Figure 4: Coarse pearlite in annealed malleable iron
the same hardness. The higher tensile strength of
ductile irons compared to gray cast iron requires
Machinability – Malleable Cast Irons
better rigidity within the machining system. Tool per-
formance life may be slightly lower if run at The machinability of malleable iron is considered to
gray cast iron surface speeds. be better than that of free-cutting steel. Use low-
strength ductile iron machining recommendations.
Ductile cast irons can be productively turned and
milled with multi-layered alumina and TiCN or PVD Austempered ductile irons (ADI) (ASTM A897-90)
TiALN-coated inserts but at slightly slower speeds are used as cast, but some castings are heat
than gray cast irons. treated to achieve desired properties. Austempered
ductile irons are produced from conventional
Malleable cast irons (ASTM A602 and A47)
ductile iron through a special two-stage heat
consist of uniformly dispersed and irregularly
Photomicrographs courtesy of Buehler Ltd., Lake Bluff, Illinois, USA, www.buehler.com
35
Metallurgy and Machinability

treatment. The microstructure consists of Compacted graphite iron (CGI) (ASTM A842)
spheroidal graphite in a matrix of acicular ferrite has a microstructure in which the graphite is
and stabilized austenite (called ausferrite) (Figure interconnected like the flake graphite in gray cast
5). The fine-grained acicular ferrite provides an iron, but the graphite in CGI is coarser and more
exceptional combination of high tensile strength with rounded (Figure 6). In other words, the structure of
good ductility and toughness. ADI can be given a CGI is between that of gray and ductile iron. The
range of properties through control of austempering graphite morphology allows better use of the
conditions. Compared to conventional grades of matrix, yielding higher strength and ductility than
ductile iron, ADI offers twice the tensile strength for gray irons. The interconnected graphite in CGI
a given level of elongation. provides better thermal conductivity and damping
capacity than the spheroidal graphite in ductile
iron. Although the CGI is less section-sensitive
than gray iron, high cooling rates are avoided
because of the high propensity of the CGI for
chilling and high nodule count in thin sections.

Figure 5: Austempered ductile iron

Machinability – Austempered Ductile Irons

The machinability of the softer grades of
austempered ductile iron (ADI) is equal or superior
to that of steels with equivalent strength. ADI can be Figure 6: Compacted graphite
machined complete in the soft, as-cast state before
heat treatment. This enables faster machine feeds Machinability – Compacted Graphite Iron
and speeds and significantly increases tool life. The graphite morphology in compacted graphite
As the hardness of ADI increases, tool life iron enables chipbreaking but is strong enough to
decreases substantially. For this reason, prevent powdery chip formations. This combination
only the 125/80/10 and 150/100/7 grades of ADI is ideal for good machinability. As a result, the
are machined after austempering. Processing machinability of compacted graphite iron lies
sequence for parts processed to the between that of gray iron and ductile iron for a
higher strength: given matrix structure. Use low-strength ductile iron
• cast the component machining recommendations.
• subcritically anneal to a fully ferritic matrix
• machine Photomicrographs courtesy of Buehler Ltd., Lake
Bluff, Illinois, USA, www.buehler.com
• austemper
• finish machine (if required)
• finish operations (rolling, grinding, peening,
if required)
Follow high-strength ductile iron recommendations
during machining.

36
Metallurgy and Machinability
Gray Cast Irons & Gray, Austenitic

standard

ASTM
materials UNS tensile strength ASTM
hardness ASTM ASTM A278 & ASTM ASTM
A159 &
HB 48 A126 ASME A319 A436
SAE J431
AS278

Gray Cast Irons F10001 generally below MPa 207 (30 ksi) — Class l
F10002 at or above 207 MPa (30 ksi) — Class ll
F10003 generally at or above 276 MPa (40 ksi) — Class lll
F10004 124 MPa (18 ksi) min. 187 max G1800
F10005 173 MPa (25 ksi) min. 170-229 G2500
F10006 207 MPa (30 ksi) min. 187-241 G3000
F10007 241 MPa (35 ksi) min. 207-255 G3500
F10008 276 MPa (40 ksi) min. 217-269 G4000
F11401 138 MPa (20 ksi) min. 156 20 (A-C) 20
F11501 145 MPa (21 ksi) min. 156 Class A
F11701 172 MPa (25 ksi) min. 174 25 (A-C) 25
F12101 207 MPa (30 ksi) min. 210 30 (A-C) 30
F12102 214 MPa (31 ksi) min. 210 Class B
F12401 241 MPa (35 ksi) min. 212 35 (A-C) 35
F12801 276 MPa (40 ksi) min. 235 40 (A-C)
F12802 283 MPa (41 ksi) min. 235 Class C
F12803 276 MPa (40 ksi) min. 235 40
F13101 310 MPa (45 ksi) min. 250 45 (A-C)
F13102 310 MPa (45 ksi) min. 250 45
F13501 345 MPa (50 ksi) min. 265 50 (A-C)
F13502 345 MPa (50 ksi) min. 265 50
F13801 379 MPa (55 ksi) min. 282 55 (A-C)
F13802 379 MPa (55 ksi) min. 282 55
F14101 414 MPa (60 ksi) min. 302 60 (A-C)
F14102 414 MPa (60 ksi) min. 302 60
F14801 483 MPa (70 ksi) min. — 70
F15501 552 MPa (80 ksi) min. — 80
Gray, Austenitic F41000 172 MPa (25 ksi) min. 131-183 1
F41001 207 MPa (30 ksi) min. 149-212 1b
F41002 172 MPa (25 ksi) min. 118-174 2
F41003 207 MPa (30 ksi) min. 171-248 2b
F41004 172 MPa (25 ksi) min. 118-159 3
F41005 172 MPa (25 ksi) min. 149-212 4
F41006 138 MPa (20 ksi) min. 99-124 5
F41007 172 MPa (25 ksi) min. 124-174 6
Grade, Type or Number

37
Metallurgy and Machinability
Malleable Cast Irons & Pearlitic, Martensitic

standard

materials UNS tensile strength yield strength ASTM

hardness ASTM ASTM
A602 &
HB A47 A220
SAE J158

Malleable
Cast Irons F20000 345 MPa (50 ksi) min. 220.5 MPa (32 ksi) min. 156 max. M3210
F20001 447.9 MPa (65 ksi) min. 309.7 MPa (45 ksi) min. 163-217 M4504
F20002 516.5 MPa (75 ksi) min. 345 MPa (50 ksi) min. 187-241 M5003
F20003 516.5 MPa (75 ksi) min. 379.3 MPa (55 ksi) min. 187-241 M5503
F20004 620.3 MPa (90 ksi) min. 482.2 MPa (70 ksi) min. 229-269 M7002
F20005 723.2 MPa (105 ksi) min. 586 MPa (85 ksi) min. 269-302 M8501
F22200 345 MPa (50 ksi) min. 224 MPa (32 ksi) min. 156 max. 32510
F22400 365 MPa (53 ksi) min. 241 MPa (35 ksi) min. 156 max 35018
Malleable, F22830 414 MPa (60 ksi) min. 276 MPa (40 ksi) min. 149-197 40010
Pearlitic & F23130 448 MPa (65 ksi) min. 310 MPa (45 ksi) min. 156-197 45008
Martensitic F23131 448 MPa (65 ksi) min. 310 MPa (45 ksi) min.; elongation 6% min. 156-207 45006
F23530 483 MPa (70 ksi) min. 345 MPa (50 ksi) min. 179-229 50005
F24130 483 MPa (70 ksi) min. 345 MPa (50 ksi) min. 196-241 60004
F24830 586 MPa (80 ksi) min. 483 MPa (70 ksi) min. 217-269 70003
F25530 655 MPa (95 ksi) min. 552 MPa (80 ksi) min. 241-285 80002
F26230 724 MPa (105 ksi) min. 621 MPa (90 ksi) min. 269-321 90001

Grade, Type, or Number

Ductile Cast Iron & Ductile, Austenitic

standard

ASTM
materials UNS tensile strength yield strength
hardness A395 ASTM ASTM SAE MIL-I-
AMS
HB A476 A439 A571 J434 24137
A536

Ductile Cast Iron F30000 as required as req’d DQ & T

F32800 414 MPa (60 ksi) min. 276 MPa (40 ksi) min. 170 max. 60-40-18 D4018
F33100 448 MPa (65 ksi) min. 310 MPa (45 ksi) min. 156-217 65-45-12 D4512
F33101 414 MPa (60 ksi) min. 310 MPa (45 ksi) min. 190 5315 (A)
F33800 552 MPa (80 ksi) min. 379 MPa (55 ksi) min. 187-255 80-55-06 D5506
F34100 552 MPa (80 ksi) min. 414 MPa (60 ksi) min. 163 80-60-03 5316
F34800 689 MPa (100 ksi) min. 483 MPa (70 ksi) min. 241-302 100-70-03 D7003
F36200 827 MPa (120 ksi) min. 621 MPa (90 ksi) min. 270-350 120-90-02
Ductile, Austenitic F43000 400 MPa (58 ksi) min. 207 MPa (30 ksi) min. 139-202 D-2
F43001 400 MPa (58 ksi) min. 207 MPa (30 ksi) min. 148-211 D-2B
F43002 400 MPa (58 ksi) min. 193 MPa (28 ksi) min. 121-171 D-2C
F43003 379 MPa (55 ksi) min. 207 MPa (30 ksi) min. 139-202 D-3
F43004 379 MPa (55 ksi) min. 207 MPa (30 ksi) min. 131-193 D-3A
F43005 414 MPa (60 ksi) min. 207 MPa (30 ksi) min. 202-273 D-4
F43006 379 MPa (55 ksi) min. 207 MPa (30 ksi) min. 131-185 D-5
F43007 379 MPa (55 ksi) min. 207 MPa (30 ksi) min. 139-193 D-5B
F43010 448 MPa (65 ksi) min. 207 MPa (30 ksi) min. 121-171 D-2M-1, D-2M-2
F43020 379 MPa (50 ksi) min. 207 MPa (30 ksi) min. — (B)
F43021 345 MPa (50 ksi) min. 172 MPa (25 ksi) min. — (C)

Grade, Type, or Number

38
Metallurgy and Machinability
Austempered Ductile Iron (ADI)

standard

hardness
materials UNS tensile strength yield strength
HB
ASTM
A897-90

Austempered n/a 850 MPa (125 ksi) min. 550 MPa (80 ksi) min./elongation 10% 269-321 125-80-10
Ductile Iron (ADI) n/a 1050 MPa (150 ksi) min. 700 MPa (100 ksi) min./elongation 7% 302-363 150-100-7
n/a 1200 MPa (175 ksi) min. 850 MPa (125 ksi) min./elongation 4% 341-444 175-125-4
n/a 1400 MPa (200 ksi) min. 1100 MPa (155 ksi) min./elongation 1% 388-477 200-155-1
n/a 1600 MPa (230 ksi) min. 1300 MPa (185 ksi) min. 444-555 230-185
Grade, Type, or
Number

Compacted Graphite Iron (CGI)

standard

hardness
materials UNS tensile strength yield strength
HB
ASTM
A842

Compacted n/a 250 MPa min. 175 MPa min./elongation 3% 179 Max. 250
Graphite Iron (CGI) n/a 300 MPa min. 210 MPa min./elongation 1.5% 143-207 300
n/a 350 MPa min. 245 MPa min./elongation 1.0% 163-229 350
n/a 400 MPa min. 280 MPa min./elongation 1.0% 197-255 400
n/a 450 MPa min. 315 MPa min./elongation 1.0% 207-269 450
Grade, Type, or
Number

Nickel (Ni) Hard / White Cast Iron

standard

hardness
materials UNS properties
HB
ASTM
A532 (class)

Austempered F45000 nickel-chromium irons 550-600 (I) A, Ni hard

Ductile Iron (ADI) F45001 nickel-chromium irons 550-600 (I) B, Ni hard
F45002 nickel-chromium irons 550-600 (I) C, Ni hard
F45003 nickel-chromium irons 400-600 (I) D, Ni hard
F45004 chromium-molybdenum irons 400-600 (II) A, white iron
F45005 chromium-molybdenum irons 400-600 (II) B, white iron
F45006 chromium-molybdenum irons 400-600 (II) C, white iron
F45007 chromium-molybdenum irons 400-600 (II) D, white iron
F45008 chromium-molybdenum irons 400-600 (II) E, white iron
F45009 chromium-molybdenum irons 400-600 (III) A, white iron
Grade, Type, or
Number

39
Metallurgy and Machinability
Cast Iron Cross-Reference / Workpiece Comparison Table

UNS USA Australia Belgium Denmark France

Gray Cast Iron

ASTM 48, ASME SA278, ASTM A159, SAE J431
F10004 G1800
F10005 G2500

F10006 G3000
F10007 G3500
F10008 G4000
F11401 20-A T150 FGG10 GG10 FGL150
20 FGG15 GG15 FGL150A
F11701 25-A FGL200A
25 FGL250A
F12101 30-A T220 FGG20 GG20 FGL200
30
F12401 35-A FGG25 GG25 FGL250
35 FGL300A

F12801 40-A
F13101 45-A FGG30 GG30 FGL300
45 FGL350A
FGL400A
F13501 50-A FGG35 GG35 FGL350
50
F13801 55-A FGG40 GG40
50
F14101 60-A FGL400
60
Gray, Austenitic
ASTM A436

F41000 1 L-NiCuCr1562 L-NUC1562

F41001 1b L-NiCuCr1563 L-NUC1563
F41002 2 L-NiCr202 L-NC202
S-NiCr202
F41003 2b L-NC203
F41004 3 L-NiCr303
S-NiCr303
F41005 4 NiSiCr3055 L-NSC2053
L-NSC3055
F41006 5 L-Ni35 L-N35
S-NiCr353
F41007 6
Malleable Iron
ASTM 602, SAE J158, ASTM A7

F20000 M3210
M4504
M5003
M5503
M7002
M8501
F22200 32510
F22400 35018

40
Metallurgy and Machinability

Germany Great Britain International Italy Japan Sweden

Gray Cast Iron

ASTM 48, ASME SA278, ASTM A159, SAE J431
Ch130 0212-00
Ch170 0215-00
0217-00
Ch190 0219-00
Ch210 0221-00
Ch230 0223-00
GG-10 100 100 G10 FC10-1 0110-00
150 150 FC15-2
GG-15 180 G15

GG-20 200 200 G20 FC20-3

220 250 G25 FC250-4

250
260
GG-25 FC25-4 0125-00
GG-30 300 300 G30 FC30-5

GG-35 350 350 G35 FC350-6

400

Gray, Austenitic
ASTM A436

GGL-NiCuCr1562 F1 L-NiCuCr1562
GGL-NiCuCr1563 F1 L-NiCuCr1563
GGL-NiCr202 F2 L-NiCr202 0523-00
L-NiCr202
GGL-NiCr203 F2 L-NiCr203
GGL-NiCr303 F3 L-NiCr303

GGL-NiSiCr3055 L-NiSiCr2053
L-NiSiCr3055
L-Ni35

S2
Malleable Iron
ASTM 602, SAE J158, ASTM A7

41
Metallurgy and Machinability
Cast Iron Cross-Reference / Workpiece Comparison Table

UNS USA Australia Belgium Denmark France

Ductile Cast Iron

ASTM A395, ASTM A476, ASTM A536, SAE J434

F32800 60-40-18 370-17 FNG38-17 715 FGS350-22

D4018 716 FGS350-22L
FGS400-15
FGS400-18
FGS400-18L
F33100 65-45-12 400-12 FNG42-12
D4512
F33101 5315
F33800 80-55-06 500-7 FNG50-7 727 FGS500-7
D5506
F34100 5316
F34800 100-70-03 700-0 FNG70-2 707 FGS700-2
D7003 800-2 FNG80-2 708 FGS800-2
F36200 120-90-02 FGA900-2
Ductile Cast Iron, Austenitic
ASTM A439
F43000 D-2 S-NC202

F43001 D-2B L-NiCr203 S-NC203

S-NiCr203
F43002 D-2C S-Ni22 S-N22
F43003 D-3 S-NC303
F43004 D-3A S-NiCr301 S-NC301
F43005 D-4 S-NiSiCr3055 S-NSC3055
F43006 D-5 S-Ni35 S-N35
F43007 D-5B S-NC353
D-5S
F43010 D-2M-1 S-NM234
D-2M-2

42
Metallurgy and Machinability

Germany Great Britain International Italy Japan Sweden

Ductile Cast Iron

ASTM A395, ASTM A476, ASTM A536, SAE J434

GGG-40 350/22 350-22 GS370-17 FCD37-0

350/22L40 350-22L FCD40-1 0717-00
400/18 400-15 0717-02
400/18L20 400-18 0717-15
400-18L
GGG-50 GS400-12 FDC45-2

GGG-60 500/7 500-7 GS500-7 FCD50-3 0727-02

FCD60-4

GGG-70 700/2 700-2 GS700-2 FCD70-5

800/2 800-2 GS800-2 FCD80-6
GGG-80 900/2 900-2
Ductile Cast Iron, Austenitic
ASTM A439

GGG-NiCr202 S2 S-NiCr202
S2W
GGG-NiCr203 S2B S-NiCr203

GGG-Ni22 S2C S-Ni22

GGG-NiCr303 S3 S-NiCr303
GGG-NiCr301 S3 S-NiCr301
GGG-NiSiCr3055 S-NiSiCr3055
GGG-Ni35 S-Ni35
GGG-NiCr353 S-NiCr353

GGG-NiMn234 S2M S-NiMn234

43
Expert Application Advisor – Cast Irons
Gray Cast Iron and Austenitic, Gray Iron (120-320 HB)
ASTM: A48I: class 20, 25, 30, 35, 40, 45, 50, 55, 60
ASTM: 126: class A, B, C
ASTM: A159 & SAE: J431; G1800, G2500, G3000, G3500, G4000
ASTM: A436; 1, 1b, 2, 2b, 3, 4, 5, 6

Material Characteristics workpiece breakout

• out-of-balance condition may exist 1. Use PVD-coated grade KC5010 at
• chucking on cast surface can be difficult moderate to low speeds.
• tendency to break out during exit from cut 2. Reduce feed rate during exit.
• contains abrasive elements; sand may be 3. Pre-chamfer casting edge at exit.
embedded in the cast surface 4. Increase toolholder lead angle.
• potential for chatter on thin wall sections workpiece chatter
• corners and thin sections can be chilled 1. Use a smaller nose radius.
(hard and brittle) 2. Apply insert geometries that are free-cutting,
• potential scale, inclusions such as MG-FN and MG-RP.
3. Increase feed to stabilize workpiece.
Common Tool Application Considerations 4. Shorten toolholder or bar overhang.
Problems & Solutions 5. Check toolholder and workholding
excessive edge wear system for rigidity.
1. Use grade KC9315 or KT315 if running at 6. Use Top Notch Turning (GX-T style) insert for
moderate to high speeds. increased tooling rigidity.
2.. Use silicon nitride-based ceramic grades Kyon
3500 or Kyon 1310, or PCBN grades, if running
at ultra-high speeds. Machining system must
have the rigidity and horsepower required to
run at ultra-high speeds.
3. Increase the feed to reduce in-cut time.
chipping
1. Increase toolholder lead angle.
2. Use a grade with good edge strength,
such as grade KC9325.
3. Ensure proper insert seating.
4. Use strong, negative-rake insert geometries
such as MA, GX-T or GA-T.
5. Use inserts with an MT-land edge prep.

44
Expert Application Advisor – Cast Irons
Ductile Iron (120-320 HB)
ASTM: A395, A476, A536; 60-40-18, 65-45-12, 80-55-06, 80-60-03, 100-70-03, 120-90-02
SAE: J434; DQ & T, D4018, D4512, D5506, D7003
AMS: 5315, 5316
ASTM: A439. A571; D2, D2B, D2C, D3, D3A, D4, D5, D5B, D2M

Material Characteristics
• graphite is in spherical form, rather than flake • machining difficulties may develop from flank
form customary in gray cast iron and crater wear on the tool
• hard spots are common concentrations of • higher tensile strength requires good rigidity
carbide in the structure in machining system
• workpiece material structure may • decreased tool life should be expected,
vary dramatically compared to machining gray or malleable
cast iron
Malleable Cast Iron (120-320 HB)
ASTM: A47: 32510, 35018
ASTM: A602 & SAE J158; M3210, M4504, M5003, M5503, M7002, M8501
ASTM: A220; 40010, 45008, 45006, 50005, 60004, 70003, 80002, 90001

Material Characteristics
• graphite is in irregular-shaped nodules, rather • generally easy to machine at
than flake form customary in gray cast iron aggressive conditions.

Common Tool Application Considerations chipping

Problems & Solutions 1. Use a strong negative-rake insert geometry.
excessive edge wear Apply the MX-T, GA-T, or MA insert geometry
as a first choice; use MG-UN insert geometry
1. Apply grade KC9315 to achieve higher speeds
as a second choice.
and longer tool life.
2. Select a T-land or large hone edge prep for
2. Use grade KC9325 for general purpose and
greater edge strength.
interrupted cutting.
3. Increase toolholder lead angle.
3. Apply grade KC9315 or KT315 if edge wear is
excessive in smooth cuts. 4. Reduce toolholder or boring bar overhang.
4. Use ceramic grade Kyon 3400. Increase speed 5. Ensure proper insert seating.
and make sure the machining set up and work- 6. Apply grade KC9325.
part clamping is rigid. 7. Use grade KC9325, increase speed, and
5. Increase feed to reduce time in cut. decrease feed when cutting with interruptions.
crater wear 8. Choose grade Kyon 3500 to replace Kyon 3400
1. Apply grade KC9315 or KT315. for heavy interruptions.
2. Reduce speed to lower the heat at cutting edge. catastrophic failure
3. Apply ceramic grade Kyon 3400 when 1. Reduce speed and feed.
machining at high speeds. 2. Use a T-land plus hone edge prep.
4. Apply large amounts of flood coolant. torn or dull workpiece
1. Apply insert geometries that are free-cutting
surface finish, such as the MG-FN.
2. Use a larger nose radius insert.
3. Use coated cermet grade KT315.

45
Expert Application Advisor – Cast Irons
Austempered Ductile Iron (269-444 HB)
ASTM: A897; 125-80-10, 150-100-7, 175-125-4, 200-155-1, and 230-185

Material Characteristics
• material is produced by heat treating Austempered ductile irons machine similarly to
(austempering) high-quality ductile iron high-strength ductile irons. Due to the higher
• grades 200-155-1 and 230-185 are hard strength of these materials, tool life is shortened
and not recommended for machining with compared to conventional irons. Use high-strength
carbide tooling ductile iron (>80 ksi) machining recommendations
for these materials. See KENNA PERFECT
recommendations on pages 6-13.

Compacted Graphite Iron (CGI) (179-269 HB)

ASTM: A842; Grade 250, 300, 350, 400, 450

Material Characteristics
• graphite is in compacted (vermiform) shapes
and relatively free of flake graphite
• lower hardness levels than gray irons of
equivalent strength
• hard or brittle enough to produce short chips;
not hard enough to produce powder
Compacted graphite irons are machined similar to
lower-strength ductile irons.

Kennametal Tooling System Solutions

KM Kenclamp Tooling
Catalog 2014
• Our newest quick-release (1.5 turns) clamping design
• Robust clamping design reduces chatter and improves tool life
• Ensures insert repeatability and seating
• Fewer moving parts vs. competitive systems
Request A02-132!

46
Failure Mechanism Analysis
Edge Wear* Chipping

Corrective Action Corrective Action

• Increase feed rate. • Use more wear • Utilize stronger grade. • Check rigidity of
• Reduce speed (sfm). resistant grade. • Consider edge system.
• Apply coated grade. preparation. • Increase lead angle.

Heat Deformation Depth-of-Cut Notching

Corrective Action Corrective Action

• Reduce speed. • Reduce depth-of-cut • Change lead angle. • Apply different
• Reduce feed. (doc). • Consider edge grade.
• Use grade with higher preparation. • Adjust feed.
hot hardness.

Thermal Cracking Built-Up Edge

Corrective Action Corrective Action

• Properly apply • Reduce feed. • Increase speed • Apply coated
coolant. • Apply coated grades. (sfm). grades or cermets.
• Reduce speed. • Increase feed rate. • Utilize coolant.
• Edge prep
(smaller hone).

Crater Catastrophic Breakage

Corrective Action Corrective Action

• Reduce feed rate. • Apply coated grades • Utilize stronger • Reduce depth-of-
• Reduce speed (sfm). or cermets. insert geometry cut (doc).
• Utilize coolant. grade. • Check rigidity of
• Reduce feed rate. system.

*NOTE: Generally, inserts should be indexed when .030 flank wear is reached. If it is a finishing operation, index at .015 flank wear or sooner.

47
Machinability Data – Cast Iron

Gray Cast Iron Ductile Cast Iron

The ideal turning insert geometry for machining The ideal turning insert geometry for machining
gray cast iron should have the following ductile cast iron should have the following
characteristics: characteristics:
• square or diamond shaped for • square or diamond shaped for
maximum strength maximum strength
• negative insert geometry for maximum • negative insert geometry for maximum strength
strength and number of cutting edges and number of cutting edges
• minimum or no positive-rake chip-forming • positive-rake chip-forming insert geometry for
insert geometry for maximum edge strength freer cutting action and chip control
• medium edge hone on carbide inserts • light edge hone on carbide inserts and a T-land
and a T-land edge prep on ceramic/sialon-grade edge prep on ceramic/sialon-grade inserts
inserts

Pre-chamfer workpiece whenever possible to avoid

workpiece material breakout and interrupted cut
shock damage to insert edge.

48
Insert Edge Preparation
Edge Preparation for Kennametal’s Advanced Cutting Tool Materials
Edge preparation is the term for the intentional There is a tradeoff to the benefits of this edge
modification of the cutting edge of an indexable preparation. Increasing the width “T” of the T-land or
insert to enhance its performance in a the angle “A” increases the overall cutting forces
metalcutting operation. acting on the insert. This can negatively affect
Ceramic cutting tool materials have a much the wear rate of the insert and/or deformation of
higher hardness, but lower toughness, compared a thin-walled workpiece.
to conventional carbide materials. Because of this, For most cast iron turning applications, use a T-land
ceramic materials have good bulk strength but width smaller than the feed rate. For heavily
lower edge strength versus carbide. interrupted turning, hard turning (workpiece >50
To optimize performance of ceramic cutting tools, HRC), and milling applications, use a T-land width
it is critical that tool material, workpiece material, larger than the feed rate.
and machining conditions be considered relative to 2. Hone
edge preparation. To achieve optimum edge Hones protect the insert cutting edge by
preparation, make the minimum amount of eliminating the sharp edge and distributing the
modification necessary to distribute forces cutting forces over a larger area. Hones generally
sufficiently enough to prevent chipping and are recommended for continuous or finishing
catastrophic insert failure. Edge preparations for operations; however, depending on the workpiece
standard inserts made with specific ceramic grades material, they can be used for interrupted or
are determined by target applications and listed in heavy cutting.
the KENNA PERFECT insert selection system.
There are three choices of edge preparation for
ceramic materials:

3. T-land plus hone

In aggressive applications, such as interrupted
turning, chipping can occur at the intersection of
1. T-land
the T-land and flank surface of the ceramic insert.
2. hone This condition may be eliminated by applying a
3. T-land plus hone small hone to the intersection while leaving the
other attributes of the T-land unchanged.
1. T-land
T lands protect the insert cutting edge by directing
forces into the greater part of the insert, rather
than to the smaller cross section of the sharp
edge, during the metalcutting process. This helps
prevent chipping and catastrophic failure.

49
Chip Control Geometries

Kenloc Inserts

insert feed rate – inches

operation style insert .0015 .0025 .004 .006 .010 .016 .025 .040 .060 .100 .200
geometry profile
.004 .006 .010 .016 .025 .040 .060 .100 .160 .250 .500
application depth of cut – inches

.008 - .016
wiper, MG-FW (0,2 - 0,4)
finishing .010 - .080
(0,3 - 2,0)

wiper, .012 - .024

medium MG-MW (0,3 - 0,6)
.030 - .200
machining (0,8 - 5,1)

wiper, MM-RW .010 - .050

(0,3 - 1,3)
roughing (single sided) .050 - .500
(1,3 - 12,7)

.005 - .012
finishing MG-FN (0,1 - 0,3)
.010 - .100
(0,3 - 2,5)

.008 - .020
medium MG-UN (0,2 - 0,5)
machining .030 - .150
(0,8 - 3,8)

.010 - .025
roughing MG-RP (0,3 - 0,6)
.045 - .250
(1,1 - 6,4)

.010 - .025
roughing MG-RN (0,3 - 0,6)
.045 - .250
(1,1 - 6,4)

heavy MM-RM .010 - .040

(0,3 - 1,0)
roughing (single sided) .050 - .500
(1,3 - 12,7)

heavy MM-RH .015 - .050

(0,4 - 1,3)
roughing (single sided) .050 - .500
(1,3 - 12,7)

feed rate – (mm)

0,04 0,063 0,01 0,16 0,25 0,4 0,63 1,0 1,6 2,5 5,0
0,1 0,16 0,25 0,4 0,63 1,0 1,6 2,5 4,0 6,3 10,0
depth of cut – (mm)

50
Chip Control Geometries

Screw-On Inserts

insert feed rate – inches

style/ insert .0015 .0025 .004 .006 .010 .016 .025 .040 .060 .100 .200
operation profile
geometry .004 .006 .010 .016 .025 .040 .060 .100 .160 .250 .500
application depth of cut – inches

.003 - .013
wiper, MT-FW (0,1 - 0,3)
finishing .008 - .060
(0,2 - 1,5)

wiper, .005 - .020

medium MT-MW (0,1 - 0,5)
.016 - .130
machining (0,4 - 3,3)

.003 - .010
fine
MT-11 (0,1 - 0,3)
finishing .008 - .050
(0,2 - 1,3)

.002 - .010
fine MT-UF (0,1 - 0,3)
finishing .005 - .050
(0,1 - 1,3)

.007 - .015
finishing MT-LF (0,2 - 0,4)
.030 - .090
(0,8 - 2,3)

.009 - .017
medium MT-MF 0,2 - 0,4
machining .045 - .090
1,1 - 2,3

feed rate – (mm)

0,04 0,063 0,01 0,16 0,25 0,4 0,63 1,0 1,6 2,5 5,0
0,1 0,16 0,25 0,4 0,63 1,0 1,6 2,5 4,0 6,3 10,0
depth of cut – (mm)

51
Kennametal Grade System for Cutting Materials
Cermet – (CERamics with METallic binders)
grade coating composition and application C class ISO class
KT315 composition: A multi-layered, PVD TiN/TiCN/TiN, coated cermet turning grade.
application: Ideal for high-speed finishing to medium machining of most carbon and alloy steels
and stainless steels. Performs very well in cast and ductile iron applications too. Provides long and K10 - K20
C3
M10 - M20
consistent tool life and will produce excellent workpiece finishes. C7
P10 - P20

PVD Coated Carbide Grades

grade coating composition and application C class ISO class

KC5010 composition: A PVD TiAlN coating over a very deformation-resistant unalloyed, carbide substrate.
application: The KC5010 grade is ideal for finishing to general machining of most workpiece
K10 - K20
materials at higher speeds. Excellent for machining most steels, stainless steels, cast C3
M10 - M20
irons, non-ferrous materials and super alloys under stable conditions. It also performs C4
P10 - P20
well machining hardened and short chipping materials.

CVD Coated Carbide Grades

grade coating composition and application C class ISO class

KC9315 composition: A multi-layered CVD coating with a very thick K-MTCVD layer of TiCN, for
maximum wear resistance, is applied over a substrate specifically engineered for cutting cast
and ductile irons.
C3 - C4 K10 - K25
application: The KC9315 grade delivers longer tool life when high-speed machining ductile
and cast irons. The thick K-MTCVD TiCN coating ensures a tremendous tool life advantage,
especially when cutting higher tensile strength ductile and cast irons where workpiece size
consistency and reliability of tool life are critical. This new Kennametal grade is excellent when
used for either straight or lightly interrupted cut applications. Moreover, if you’re looking for high
productivity performance, the KC9315 grade is an ideal choice.
KC9325 composition: A TiCN and alumina-coated grade with a strong, reliable substrate.
application: Grade development for the KC9325 grade focused on a variety of ductile and
cast iron operations. The coating and substrate are optimized for flexibility. If you are machining
C2 - C3 K15 - K30
different types of ductile or cast irons where application confidence, flexibility and broad
range reliability are your primary requirements, the KC9325 grade is the perfect choice.

Silicon Nitride-Based Ceramic

grade coating composition and application C class ISO class

KY1310* composition: An advanced sialon ceramic grade.

application: Grade KY1310 provides maximum wear resistance. Use it for
high-speed continuous turning of gray cast iron, including through scale.
– K05-K15
*KY1310 will be available January 2004.

KY3400 composition: CVD coated pure silicon nitride grade.

application: Excellent combination of toughness and edge wear resistance; used for general
C3 K10 - K30
purpose machining of gray cast irons and ductile or nodular cast irons.

KY3500 composition: Pure silicon nitride grade.

application: Maximum toughness; used at high feed rates for rough machining of gray cast iron,
including machining through interruptions. K15 - K35
C2
M15 - M30

PCBN – Polycrystalline Cubic-Boron Nitride

grade coating composition and application C class ISO class
KB9640 composition: A high CBN content, solid PCBN structure having multiple cutting edges and a CVD
alumina coating.
application: The KB9640 grade is applied in the roughing to semi-finishing of fully pearlitic gray
cast iron, chilled irons, high chrome alloy steels, sintered powdered metals, and heavy cuts in hard- C1 K05-K15
ened steels (>45 HRC). Use for finished chilled cast iron and fully pearlitic cast iron. Do not apply on
finishing hardened steels. KB9640 can be applied effectively when roughing hardened steels.

52
Kennametal Grade System for Cutting Materials

Gray Cast Irons Ductile Cast Irons

Ceramic Cutting Tools Ceramic Cutting Tools

KY3500“

Carbide Cutting Tools Carbide Cutting Tools

53
KENNAMETAL
TOOL MANAGEMENT SOLUTIONS
No matter how intricate your metalworking manufacturing
operations or equipment, Kennametal’s new ToolBoss
System, powered by our exclusive, built-to-suit ATMS
software, will enable your machinists to spend more
time machining parts — far less energy locating tools.

ToolBoss™™ System
Our unique, new, easy-to-use/
easy-to-audit tool dispenser
can help reduce your:

■ tool-buying costs by as much as 90%!

■ tool-inventory costs by up to 50%!

■ tool-supply costs by nearly 30%!

www.kennametal.com

54
Technical
Information
page

Wiper Insert Application Guidelines . . . . . . . . . . . 56

Conversion Tables . . . . . . . . . . . . . . . . . . . . . . . . . 60

Nose Radius Selection for Surface Finish . . . . . . . . . . . 61

Insert Size Selection Guide ...................... 62

Tool Performance Report Form .................... 63

Insert Identification System . . . . . . . . . . . . . . . . . . . . . . . . 66

55
 Three Ways To
Improve Your
Turning Operations!
Kennametal introduces three new geometries that are the
latest in state-of-the-art turning technology. Our new -RW
(Roughing Wiper), -MW (Medium Wiper) and -FW (Finishing
Wiper) inserts employ a modified corner radius design that
delivers a superior surface finish compared to conventional
inserts. This technology allows you to choose the metalcutting
benefit that’s most important to your application.

Double Productivity
Kennametal’s new wiper geometries allow you to double your
current feed rate and still achieve surface finishes comparable
to conventional inserts. You’ll also see equivalent or better tool
life using the appropriate KENNA PERFECT grade specifically
designed for your workpiece material.

Better Workpiece Finish

These new wiper geometries also will give you a markedly improved
surface finish at your current machining conditions. Under typical
conditions, you’ll see as much as
a 250% improvement in the
workpiece surface finish, all
with inserts that meet your
corner radius specifications.

You choose! Either way,

we’re sure you’ll agree that the
new wiper geometries from
Kennametal provide an
outstanding way to optimize
your turning operations.
Please see the accompanying
information for proper
application guidelines.

Kennametal Wiper
Technology –MW
Conventional doc ................0.050
Turning Insert feed ................0.020 ipr
doc ............0.050 speed..............1,100 sfm
feed ..........0.012 ipr finish ..............60 Ra (µ in.)
speed ........1,100 sfm
finish ........160 Ra (µin.)

56
Negative Wiper Inserts – Application Technology
Surface Finish

Theoretical Surface Finish – Ra

µin. (µm)

insert feed rate – ipr (mm/rev)

FW , MW, .008 .012 .016 .020 .024 .028 .032 .036 .040 .044 .048
& RW (0,2) (0,3) (0,4) (0,5) (0,6) (0,7) (0,8) (0,9) (1) (1,1) (1,2)

14 30 50 80
3/8 IC — — — — — — —
(0,3) (0,75) (1,3) (2)

23 41 63 91 120 160 200 250

1/2 IC — — —
(0,6) (1) (1,6) (2,2) (3) (4) (5) (6,2)

103 141 184 232 287 347 413

3/4 + 1 IC — — — —
(2,6) (3,5) (4,6) (5,8) (7,2) (8,7) (10,3)

How It Works
Wiper Insert Standard Insert LEGEND
f – feed
r – corner radius
rw – wiper radius
Ra – surface finish

Corner Radius Configuration

DNMG and TNMG wiper inserts do

CNMG and WNMG wiper not provide an exact corner radius on
inserts create a true corner the workpiece. The radius produced
radius on the workpiece, just falls within a ±.0025 tolerance band.
as a standard insert does. (blue lines)

57
Negative Wiper Inserts – Application Technology
C– and W–Style Inserts Kenloc® Toolholders
surface with wiper effect
surface with standard insert edge

CN . . 80° corner CN . . 100° corner

insert requires MCLN insert requires MCRN
5° reverse lead 15° lead angle toolholder
angle toolholder

CN . . 100° corner WN . . 80° corner insert

insert requires MCKN requires MWLN 5° reverse
15° lead angle toolholder lead angle toolholder

D– and T–Style Inserts Kenloc Toolholders

surface finish with wiper effect
surface with designated insert nose radius
surface finish with .016 radius

DN . . 55° corner insert TN . . 60° corner insert

requires MDJN 3° reverse requires MTJN 3° reverse
lead angle toolholder lead angle toolholder

S–Style Inserts Kenloc Toolholders

surface with wiper effect
surface with standard insert edge

SN . . 90° corner insert SN . . 90° corner insert

requires MSRN 15° lead requires MSKN 15° lead
angle toolholder angle toolholder

NOTE: The holder guidelines above also apply to ceramic/PCBN wiper inserts in similar insert shapes; i.e.: CNGA, CNGX, DNGA, etc.

58
Positive Wiper Inserts – Application Technology
Positive geometry wiper inserts offer the same
advantages as negative style inserts. When
compared to conventional inserts, feed rates
can be doubled while maintaining surface
finish, or surface finish can be improved by a
multiple of 2.5 while maintaining productive -FW -MW
feed rates. Finishing Wiper Medium
Machining Wiper
Surface Finish
Theoretical Surface Finish – Ra
µin. (µm)
insert feed rate – ipr (mm/rev)

.002 .004 .006 .008 .010 .012 .014 .016 .018 .020
FW , MW
(0,05) (0,10) (0,15) (0,20) (0,25) (0,30) (0,35) (0,40) (0,45) (0,50)

1 6 14 22 35 49
1/4 IC — — — —
(0,03) (0,15) (0,35) (0,55) (0,90) (1,25)

1 4 8 14 22 30 39
3/8 IC — — —
(0,02) (0,10) (0,20) (0,35) (0,55) (0,75) (1,00)

1 2 6 10 16 24 31 39 51 63
1/2 IC
(0,02) (0,06) (0,15) (0,25) (0,40) (0,60) (0,80) (1,00) (1,30) (1,60)

CCMT and CPMT Inserts Screw-On Toolholders and Boring Bars

surface with wiper effect
surface with designated insert
nose radius

C.MT 80° inserts require 5° reverse lead C.MT 100° inserts

SCL toolholders. require 15° lead
SCK toolholders.

DCMT– and DPMT–Style Inserts

surface finish with wiper effect
surface with designated insert nose radius
surface finish with .016 radius

SDN SDU SDJ

D.MT 55° inserts require a 3° reverse lead angle and can be

used in SDN, SDU, and SDJ style toolholders and boring bars.

59
Application Guidelines – Cast Iron
Conversion Charts
hardness inch to metric
Brinell Rockwell Brinell Rockwell diameter Ø diameter Ø
HB HRB HRC HB HRB HRC
inches mm inches mm
654 — 60 253 101.5 25 .315 8,0 3.000 76,2
634 — 59 247 101.0 24 .374 9,5 3.150 80,0
.394 10,0 3.500 88,9
615 — 58 243 100.0 23 .472 12,0 3.937 100,0
595 — 57 237 99.0 22 .500 12,7 4.000 101,6
577 — 56 231 98.5 21 .626 15,9 4.921 125,0
560 — 55 228 98.0 20 .630 16,0 5.000 127,0
543 — 54 222 97.0 18.6 .752 19,1 6.000 152,4
.787 20,0 6.299 160,0
525 — 53 216 96.0 17.2 .874 22,2 7.000 177,8
512 — 52 210 95.0 15.7 .984 25,0 7.874 200,0
496 — 51 205 94.0 14.3 1.000 25,4 8.000 203,2
481 — 50 200 93.0 13 1.260 32,0 9.842 250,0
1.500 38,1 10.000 254,0
469 — 49 195 92.0 11.7 1.968 50,0 12.000 304,8
455 — 48 190 91.0 10.4 2.000 50,8 12.401 315,0
443 — 47 185 90.0 9.2 2.480 63,0 14.000 355,6
432 — 46 180 89.0 8 2.500 63,5 15.748 400,0
421 — 45 176 88.0 6.9
409 — 44 172 87.0 5.8 Turning Formulas
400 — 43 169 86.0 4.7 to find formula
390 — 42 165 85.0 3.6
381 — 41 162 84.0 2.5 d x rpm
sfm 3.82
371 — 40 159 83.0 1.4
362 — 39 156 82.0 .30 sfm x 3.82
rpm d
353 — 38 153 81.0 —
344 — 37 150 80.0 — mpm sfm ÷ 3.27
336 109.0 36 147 79.0 —
327 108.5 35 144 78.0 — sfm mpm x 3.27
319 108.0 34 141 77.0 —
311 107.5 33 139 76.0 — ipm
ipr rpm
301 107.0 32 137 75.0 —
294 106.0 31 135 74.0 — ipm ipr x rpm
286 105.5 30 132 73.0 —
279 104.5 29 130 72.0 — mm inch x 25.4
271 104.0 28 127 71.0 —
264 103.0 27 125 70.0 — inches mm ÷ 25.4
258 102.5 26 123 69.0 —
cut loc
NOTE: Values in shaded areas are beyond normal range and time ipr x sfm (minutes)
given for information only.

Abbreviations
doc speed
inches mm sfm m/min. sfm = surface feet per minute
.010 0,254 300 91
.015 0,381 400 122 rpm = revolutions per minute
.030 0,762 500 152
.050 1,270 600 183 mpm = meters per minute
.100 2,540 800 244
.125 3,175 1000 305
.150 3,810 1200 366 ipr = inches per revolution
.250 6,350 2000 610
4000 1219 ipm = inches per minute
.375 9,525 10000 3048
.500 12,700
d = diameter
feed surface finish (Ra)
ipr mm/rev mm = millimeters
µ inch µm
.003 .076 492 12,5 loc = length of cut
.005 .120 248 6,3
.005 .127 126 3,2
.006 .152 63 1,6
.007 .178 31 0,8
.008 .203 16 0,4
.009 .229
.010 .254
.011 .279
.012 .305
60
Application Guidelines – Cast Iron
Nose Radius Selection and Surface Finish for Conventional Inserts*

1 2

Nose radius and feed rate have the greatest impact

on surface finish. To determine the nose radius
required for a theoretical surface finish, use the
following procedure and the chart above.
1 Locate the required surface finish (rms or AA)
on the vertical axis.
2 Follow the horizontal line corresponding to the
desired theoretical finish to where it
intersects the diagonal line corresponding
to the intended feed rate.
3 Project a line downward to the nose radius
scale and read the required nose radius.
NOTE: Peaks produced with a small radii insert (top) compared
4 If this line falls between two values, choose to those produced with a large radius insert (bottom).
the larger value.
• If no available nose radius will produce the
required finish, feed rate must be reduced.
• Reverse the procedure to obtain surface
finish from a given nose radius.
*NOTE: See pages 57-59 for radius and surface
finish specifications using wiper-style inserts.
61
Insert Size Selection Guide
Cast Iron Geometries

maximum depth of cut

cutting finishing roughing

general purpose
insert shape IC edge MG-FN MG-UN MX-T0820
length MG-FW MG-RP ..MA
MA-T0820 MG-MW – S0820
T0420-FW
C-80° Diamond .250 .250 .050
.375 .375 .075 .150
.500 .500 .120 .250 .250
.625 .625 .313 .313
.750 .750 .375 .375
1.000 1.000 .500 .500
D-55° Diamond .250 .275 .030
.375 .433 .060 .125 .150
.500 .590 .100 .175 .200
.625 .748

R-Round .375 .188 .112 .112

.500 .250 .200 .200
.625 .313 .250 .250
.750 .375 .300 .300
1.000 .500 .400 .400

S-Square .375 .375 ..075 .150 .150

.500 .500 ..120 .250 .250
.625 .625 .313 .313
.750 .750 .375 .375
1.000 1.000 .500 .500

T-Triangle .250 .433 .030

.375 .630 .060 .125 .150
.500 .866 .100 .175 .200
.625 1.060 .250 .300

V-35° Diamond .375 .630 .045 .060 .070

.500 .866 .120

W-Trigon .250 .157

.375 .236 .075 .100 .120
.500 .315 .100 .150 .200

62
Turning Tool Performance Report

COMPANY & LOCATION DATE ENGINEER

CUSTOMER NAME MATERIAL TYPE AND CONDITION HARDNESS

PART DESCRIPTION CUTTING CONDITION (CIRCLE)

MACHINE & TYPE

OPERATION CONDITION OF MACHINE HP CONSTANT SFM

■ YES ■ NO

PART CONFIGURATION
COMMENTS

PERFORMANCE, TECHNICAL & COST DATA TEST 1 TEST 2 TEST 3

1 OPERATION NUMBER
2 TURRET POSITION
3 TOOLHOLDER
4 INSERT STYLE
5 GRADE
6 DEPTH OF CUT
7 LENGTH OF CUT
8 FEED RATE (IPR)
9 WORKPIECE DIAMETER
10 CUTTING SPEED RPM
SFM
11 CUTTING TIME PER PIECE (MINUTES) (30 SECONDS = .5)
12 PIECES PER EDGE
13 CUTTING TIME PER EDGE (MINUTES) (11 x 12)
14 CUTTING EDGES PER INSERT
15 PIECES PER INSERT (14 x 12)
16 REASONS FOR INDEXING
17 TYPE OF COOLANT
18 HORSEPOWER REQUIRED
19 FINISH (RMS)
20 CHIP CONTROL (GOOD, FAIR, POOR)
21 INSERT COST
22 INSERT COST PER PIECE (21 ÷ 15)
23 MACHINE COST PER HOUR
24 MACHINE COST PER PIECE (11 x 23 ÷60)
25 TOTAL COST PER PIECE (24 + 22)
26 ESTIMATED ANNUAL PRODUCTION – PIECES
27 ESTIMATED ANNUAL COST (26 x 25)
28 ESTIMATED ANNUAL SAVINGS

63
 KENNA PERFECT
Inserts

Steel
Stainless Steel
Cast Iron
Non-Ferrous Metals
High-Temperature Alloys
Hardened Materials

64
Table of
Contents
page

Insert Identification System . . . . . . . . . . . . 66

Kenloc® Negative Inserts . . . . . . . . . . . . . . . . 68

Screw-On Inserts . . . . . . . . . . . . . . . . . . . . . . . 81

Top Notch® Turning Inserts . . . . . . . . . . . . . . . . . 91

Kendex® Inserts . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

65