Presentation

OLARRA S.A.OLARRA S.A.

MECAMAXMECAMAXSTAINLESS STEEL WITH IMPROVED MACHINABILITYSTAINLESS STEEL WITH IMPROVED MACHINABILITY

MAQUINABILITY FACTORSMAQUINABILITY FACTORS

MATERIAL

Chemical

Composition

Mechanical characteristics

Structure

Inclusions

MAQUINA

Type

Power

Conditions

HERRAMIENTA

Composition

Geometry

Chip Breaker

CONDICIONES

Speed

Feed

Depth

Lubrication

THE TOOLTHE TOOL

• TYPE OF MATERIALTYPE OF MATERIAL– HIGH SPEED STEELHIGH SPEED STEEL– CARBIDE TOOLCARBIDE TOOL– COATED CARBIDE TOOLCOATED CARBIDE TOOL– EDGE DIAMOND COVEREDEDGE DIAMOND COVERED

• DESINGDESING– GEOMETRY : GEOMETRY : POSITIVE (Cut)POSITIVE (Cut)

NEGATIVE (Pull out)NEGATIVE (Pull out)

– CHIP BREAKERS CHIP BREAKERS

FEATURES FOR SELECTIONFEATURES FOR SELECTION

• MATERIAL TO MACHINEMATERIAL TO MACHINE• TYPE OF MACHININGTYPE OF MACHINING• TYPE OF OPERATIONTYPE OF OPERATION

– FINISHING, ROUGH.FINISHING, ROUGH.

• CONDITIONSCONDITIONS – CONTINUOUS CUTCONTINUOUS CUT– UNCONTINUOUS CUTUNCONTINUOUS CUT

MAIN CHARACTERISTICS MAIN CHARACTERISTICS

NL 92NL 92 NL 30NL 30 NL 25NL 25

TENACITY TENACITY HARDHARD

SHOCK RESISTENCESHOCK RESISTENCE

HITHIT

VIBRATIONSVIBRATIONS

RESISTENCE AGAINST TOOL WEARRESISTENCE AGAINST TOOL WEAR

HIGH SPEEDHIGH SPEED

CONTINUOUS CUTCONTINUOUS CUT

COATED CARBIDE TOOLCOATED CARBIDE TOOL

HIGH CUTTING TEMPERATURE AND HIGH TOOL WEAR REDUCTIONHIGH CUTTING TEMPERATURE AND HIGH TOOL WEAR REDUCTION

TOOLS GEOMETRYTOOLS GEOMETRY

• CUTTING ANGLECUTTING ANGLE

– POSITIVE POSITIVE

– WITH UNCONTINUOUS CUTTING NEGATIVE WITH UNCONTINUOUS CUTTING NEGATIVE

• CHIP BREAKERCHIP BREAKER

– WITHOUT SHOCK: GEOMETRY 61WITHOUT SHOCK: GEOMETRY 61

– WITH LIGHT SHOCK: GEOMETRY 2NWITH LIGHT SHOCK: GEOMETRY 2N

– WITH HEAVY SHOCK: GEOMETRY 4TWITH HEAVY SHOCK: GEOMETRY 4T

GEOMETRYGEOMETRY

DIFFERENT KIND OF TOOLSDIFFERENT KIND OF TOOLS

EL CUTTING FLUIDSEL CUTTING FLUIDS

• LUBRICATE AND REDUCE THE LUBRICATE AND REDUCE THE FRICTIONFRICTION

• COOL THE MATERIAL AND THE TOOLCOOL THE MATERIAL AND THE TOOL– Protection against oxidationProtection against oxidation– Tool wear reductionTool wear reduction– Enhaces chip removalEnhaces chip removal– Improvement in dimensional Improvement in dimensional

tolerancetolerance

SELECTION OF THE CUTTING FLUIDSELECTION OF THE CUTTING FLUID

• MATERIAL SEVERITYMATERIAL SEVERITY

• MACHINING OPERATION SEVERITYMACHINING OPERATION SEVERITY

• TEMPERATURE LIMIT FOR TOOL USETEMPERATURE LIMIT FOR TOOL USE

• CUTTING SPEEDCUTTING SPEED

• TOOLING AND FIXTURESTOOLING AND FIXTURES

NEW TENDENCY FOR CUTTING FLUIDSNEW TENDENCY FOR CUTTING FLUIDS

• HIGHER USE OF WATER SOLUBLE HIGHER USE OF WATER SOLUBLE FLUIDSFLUIDS– RentabilityRentability– Faster coolingFaster cooling

• SINTETIC CUTTING FLUIDSSINTETIC CUTTING FLUIDS– New technology that avoids the New technology that avoids the

machinability of all ferrous materialsmachinability of all ferrous materials– Greater duration and microbiologic Greater duration and microbiologic

resistenceresistence– Greater grateful use Greater grateful use

CHOOSE THE SELECTION OF CUTTING CHOOSE THE SELECTION OF CUTTING FLUIDS FOR EACH CONDITIONSFLUIDS FOR EACH CONDITIONS

Grinding

Milling

Turning

Drilling

Machining of gears

Broaching

SYNTILO XPSSYNTILO XPS

SYNTILO GXSYNTILO GX

Cast Iron Steel Alloy Steel Stainless Steel NiquelCast Iron Steel Alloy Steel Stainless Steel Niquel

MACHINING PARAMETERSMACHINING PARAMETERS

• CUTTING SPEEDCUTTING SPEED

• DEPTH OF CUTDEPTH OF CUT

• FEEDFEED

• ANGLE OF POSITIONANGLE OF POSITION

MACHINING CONDITIONSMACHINING CONDITIONS

• CUTTING SPEEDCUTTING SPEED– IT DEFINES THE CUTTING TEMPERATURE IT DEFINES THE CUTTING TEMPERATURE

AND THE TOOL FRICTIONAND THE TOOL FRICTION

• DEPTH OF CUTDEPTH OF CUT– IT IS LIMITED BY THE LENGTH OF THE IT IS LIMITED BY THE LENGTH OF THE

TOOL CUTTING EDGE. IT DEFINES THE CHIP TOOL CUTTING EDGE. IT DEFINES THE CHIP WIDEWIDE

• FEEEDFEEED– IT DEFINES THE CHIP THICKNESSIT DEFINES THE CHIP THICKNESS

• ANGLE OF POSITIONANGLE OF POSITION– IT DEFINES THE CHIP WIDE AND THICKNESSIT DEFINES THE CHIP WIDE AND THICKNESS

BEST CONDITIONS FOR STAINLESS STEEL BEST CONDITIONS FOR STAINLESS STEEL MACHININGMACHINING

• HIGH CUTTING SPEEDHIGH CUTTING SPEED– IT RAISES THE TEMPERATURE IN THE IT RAISES THE TEMPERATURE IN THE

CUTTING POINT AND DECREASE THE CUTTING POINT AND DECREASE THE ADHESIONADHESION

• DEEP AND FEED ADAPTED TO THE TOOL DEEP AND FEED ADAPTED TO THE TOOL GEOMETRYGEOMETRY– LOW FEED MAY INCREASE THE CHIP LOW FEED MAY INCREASE THE CHIP

LENGTHLENGTH

• ANGLE OF POSITION LESS THAN 90ºANGLE OF POSITION LESS THAN 90º– IT ALLOWS A BETTER ENTRY FOR THE IT ALLOWS A BETTER ENTRY FOR THE

TOOLTOOL

MATERIALMATERIAL

• THE QUEMICAL COMPOSITIONTHE QUEMICAL COMPOSITION

• INCLUSIONSINCLUSIONS

• MECHANICAL PROPERTIESMECHANICAL PROPERTIES

• STRUCTURESTRUCTURE

QUEMICAL COMPOSITIONQUEMICAL COMPOSITION

SULFUR CONTENTSSULFUR CONTENTS

GAINGAIN

IMPROVES MACHINABILITYIMPROVES MACHINABILITY

INCONVENIENTSINCONVENIENTS

LOWER CORROSION LOWER CORROSION RESISTENCERESISTENCE

LOWER MECHANICAL LOWER MECHANICAL PROPERTIESPROPERTIES

SULFUR = 0.300%SULFUR = 0.300%

HIGH MACHINABILITYHIGH MACHINABILITY

SULFUR < 0.030%SULFUR < 0.030%

HIGH CORROSION HIGH CORROSION RESITENCERESITENCE

MECAMAX CONCEPTMECAMAX CONCEPT

• IMPROVE MACHINABILITYIMPROVE MACHINABILITY

• NO DECREASE THE REST OF THE STEEL NO DECREASE THE REST OF THE STEEL PROPERTIESPROPERTIES

POINTS TO ACTPOINTS TO ACT

• SULFUR LEVEL CONTROLSULFUR LEVEL CONTROL

– S < 0.030 %S < 0.030 %

– S = 0.300 %S = 0.300 %

• MODIFY THE INCLUSIONSMODIFY THE INCLUSIONS

MODIFICATIONS OF THE MODIFICATIONS OF THE INCLUSIONSINCLUSIONS

• AVOID THE ABRASIVE INCLUSIONS AVOID THE ABRASIVE INCLUSIONS THAT PERJUDICE THE TOOLTHAT PERJUDICE THE TOOL

• GENERATE SOFTER INCLUSIONS AND GENERATE SOFTER INCLUSIONS AND LOWER FUSION POINTLOWER FUSION POINT– LUBRICATION FILM BETWEEN THE TOOL LUBRICATION FILM BETWEEN THE TOOL

AND THE MATERIAL AND THE MATERIAL

THE CONTACT BETWEEN THE MATERIAL AND THE TOOL THE CONTACT BETWEEN THE MATERIAL AND THE TOOL GENERATES HEATGENERATES HEAT

LUBRICATION EFFECTLUBRICATION EFFECT

IT PRODUCES THE FUSION OF THE INCLUSIONS IT PRODUCES THE FUSION OF THE INCLUSIONS

IT GENERATES THE LUBRICATION EFFECT IT GENERATES THE LUBRICATION EFFECT

PROCESS CONTROLPROCESS CONTROL

LADDLE METALURGIC

Conditions Control

Check Control

Calcium Treatment

Before treatment After calcium treatment

Calcium Globular Inclusion

( Mn Ca ) S

SiO2

Al2O3 CaO

Manganese Sulfur

Alumines

Silicoaluminates

THE CONDITIONS MUST BE THE THE CONDITIONS MUST BE THE APPROPRIATEAPPROPRIATE

• PROPER MACHINABILITY CONDITIONSPROPER MACHINABILITY CONDITIONS– HIGHER SPEEDSHIGHER SPEEDS

• TOOLS THAT ALLOW HIGH WORKING TOOLS THAT ALLOW HIGH WORKING TEMPERATURESTEMPERATURES

Tª

HSS CARBIDE

Tª FUSION INCLUSIONS

FEATURES OF MECAMAX STAINLESS FEATURES OF MECAMAX STAINLESS

• Satisfied the International StandarsSatisfied the International Standars

• Corrosion ResistenceCorrosion Resistence

• Mechanical PropertiesMechanical Properties

• Material PriceMaterial Price

SIMILITUDES WITH BASE STEELSIMILITUDES WITH BASE STEEL

FEATURES OF MECAMAX STAINLESSFEATURES OF MECAMAX STAINLESS

• Cutting speed higherCutting speed higher

• Increase the ratio of cut off materialIncrease the ratio of cut off material

• Lower tool wearLower tool wear

• Reduce machine down timeReduce machine down time

• Homogenious behaviourHomogenious behaviour

GAIN RESPECT THE BASE STEELGAIN RESPECT THE BASE STEEL

BETTER MACHINABILITYBETTER MACHINABILITY

RESULTSRESULTS

• DECREASE THE MACHINING TIMEDECREASE THE MACHINING TIME– HIGHER SPEED, FEED AND DEPTHHIGHER SPEED, FEED AND DEPTH– LESS TOOLS CHANGES LESS TOOLS CHANGES

Machinability value Standard

MECAMAX

TOOL WEAR TESTTOOL WEAR TESTCOATED CARBIDE TOOLCOATED CARBIDE TOOL

Vc = 650m/min ; a = 0.2mm/rev ; p= 1mm Without lubrication

0

50

100

150

200

250

300

350

400

Mechaniced meters

Wear (micras)

MECAMAX 303 PLUS AISI 303 304MECAMAX AISI 304

050

100150200250300350400450

SPE

ED

Mecamax303 plus

AISI 303 304Mecamax

AISI 304

TEST V20; a = 0,1 mm/rev ; p = 1 mmWITHOUT LUBRICATION

TOOL WEAR TESTSTOOL WEAR TESTSCOATED CARBIDE TOOLCOATED CARBIDE TOOL

MACHINING TESTMACHINING TESTMECAMAX 304MECAMAX 304

TURNING CuttingSpeedm/min

Depth

mm

Feed

mm/rev.

Type of tool

RoughingTurning

240 / 300 3.0 / 5.0 0.3 / 0.5 CarbideNL25 / NL 92

FinishingTurning

360 / 450 0.6 / 1.0 0.15 / 0.25 CarbideNL25 / NL 92

DRILLING Diametermm

Cutting Speedm/min

Feedmm/rev.

Coated H.S.S. 38

25 / 3525 / 35

0.080.22

Carbide 4 / 614 / 20

70 / 9070 / 90

0.05 / 0.080.12 / 0.20

Indexable InsertDriling Tools

17.5 / 2348 / 59

170 / 190170 / 190

0.06 / 0.150.10 / 0.25

SINTYLO XPS CUTTING FLUIDSINTYLO XPS CUTTING FLUID

MACHINING TESTMACHINING TESTMECAMAX 316MECAMAX 316

TURNING CuttingSpeedm/min

Depth

mm

Feed

mm/rev.

Type of tool

RoughingTurning

180 / 220 3.0 / 5.0 0.3 / 0.5 CarbideNL25 / NL 92

FinishingTurning

260 / 325 0.6 / 1.0 0.15 / 0.25 CarbideNL25 / NL 92

DRILLING Diametermm

Cutting Speedm/min

Feedmm/rev.

Coated H.S.S. 38

20 / 3520 / 35

0.080.22

Carbide 4 / 614 / 20

50/ 7050 / 70

0.05 / 0.080.12 / 0.20

Indexable InsertDriling Tools

17.5 / 2348 / 59

125 / 140125 / 140

0.06 / 0.150.10 / 0.25

SINTYLO XPS CUTTING FLUIDSINTYLO XPS CUTTING FLUID

MACHINING TESTMACHINING TESTMECAMAX 303 PLUSMECAMAX 303 PLUS

TURNING CuttingSpeedm/min

Depth

mm

Feed

mm/rev.

Type of tool

RoughingTurning

360 / 450 3.0 / 5.0 0.3 / 0.5 CarbideNL25 / NL 92

FinishingTurning

500 / 600 0.6 / 1.0 0.15 / 0.25 CarbideNL25 / NL 92

DRILLING Diametermm

Cutting Speedm/min

Feedmm/rev.

Coated H.S.S. 38

35 / 5035 / 50

0.080.22

Carbide 4 / 614 / 20

90 / 13090 / 130

0.05 / 0.080.12 / 0.20

Indexable InsertDriling Tools

17.5 / 2348 / 59

260 / 290260 / 290

0.06 / 0.150.10 / 0.25

SINTYLO XPS CUTTING FLUIDSINTYLO XPS CUTTING FLUID

BENEFITS OF MECAMAX FOR THE BENEFITS OF MECAMAX FOR THE CUSTOMERCUSTOMER

• Improved Surface Finish• Improved Dimensional Tolerances• Reduced Machine Down Time• Increased Cutting Speeds• Increased Tool Life

GREATER PRODUCTIVITYGREATER PRODUCTIVITY

LOWER COSTSLOWER COSTS