Sandvik Coromant, part of the Sandvik group headquartered in Sandviken, Sweden, has announced that it is adding two new steel-turning carbide grades – GC4415 and GC4425 – to its range in an effort to improve cutting speeds and reduce energy consumption. Sandvik Coromant has reported that an average tool life increase of 25%, in combination with reliable and predictable performance can minimise materialise waste.
GC4425 is said to deliver improved wear resistance, heat resistance and toughness, while grade GC4415 is designed to complement GC4425 when enhanced performance and more heat resistance is needed. Both grades are suitable for use with tough materials like Inconel and unalloyed stainless steel ISO-P grades that are complex and difficult to machine.
The GC4425 grade reputedly provides extremely high process security through its ability to retain an intact edge line. Because the insert can deliver more pieces per edge, fewer carbides are consumed to machine the same number of components; consistence and predictability also help to minimise material waste.
With both GC4425 and GC4415, the insert’s substrate and coating have been developed to better withstand high temperatures. Both contain a second-generation Inveio® layer, a textured chemical vapour deposition (CVD) alumina (Al2O3) coating developed for machining. Inveio creates a strong barrier towards the cutting zone and extends the life and wear resistance of tools.
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The GC4425 grade was subjected by Sandvik Coromant’s customers to pre-market tests. Among these was a general engineering company that applied both a competitor’s insert and the GC4425 insert, in the manufacture of pressure rollers. An ISO-P grade was subjected to continual external axial machining and semi-finishing at a cutting speed (vc) of 200 m/min, feed rate of 0.4 mm/rev (fn) and depth (ap) of 4 mm.
Manufacturers typically measure tool life by the number of workpieces machined. While competitor’s grade machined a reported twelve pieces before wearing out due to plastic deformation, Sandvik Coromant’s insert produced eighteen pieces and, in doing so, worked 50% longer with stable and predictable wear.
The company has stated that this illustrates the gains that can be achieved if the right machining elements are brought together. To help with process monitoring itself, Sandvik Coromant has also developed CoroPlus® Process Control software that can monitor machining in real-time and act according to programmed protocols if specific issues occur — for example, by stopping the machine or replacing a worn cutting tool.