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Greenleaf
®
GSN-100Greenleaf
®
GSN-100
Greenleaf
® GSN-100Greenleaf
® GSN-100GSN to GSN-100
Review of Silicon Nitrides
GSN-100DescriptionCurrent data and successes
TurningGray IronDuctile Iron
MillingGray IronDuctile Iron
Other applicationsGSN-100 vs. HSN-100 & 200
Silicon NitridesSilicon Nitrides
Greenleaf
® GSN-100Developed for Cast Iron Applications
• Higher thermal shock resistance when compared to Whisker Ceramics
• Lower high temperature stability compared to Whisker Ceramics
• Best in interrupted cutting due to high thermal shock resistance• Scale• Milling
Greenleaf
® GSN-100Greenleaf
® GSN-100
An engineered blend of silicon nitride and proprietary toughening agents that redefine productivity in
the machining of cast iron.
GSN100 delivers outstanding tool life at high cutting speeds in turning,
grooving and milling applications.
GSN-100 Test DataGSN-100 Test Data
GSN-100 Class 30 Gray Iron TurningGSN-100 Class 30 Gray Iron Turning
Gray Cast Iron, class 30, 20 R/CGray Cast Iron, class 30, 20 R/C
• Competitor: GC-4187 K40C• 2000 SFM (610 M/Min)• .004 IPR plunge (0,10 mm/rev)• .008 IPR turn (0,20 mm/rev)
• Greenleaf
® WG-6218-2A SG-0173• 4000 SFM (1220 M/Min)• .008 IPR plunge (0,20 mm/rev)• .012 IPR turn (0,30 mm/rev)
•This customer presently running competitor GC-4187 K40C grade and completing 15 parts per insert with a cycle time of 13.44 minutes.
•Ran test with WG-6218-2A GSN-100 insert and completed 74 parts per insert
•Cycle time 11.38 minutes
•5X greater tool life
•SFM is 2X present tool
•Feed rate is 4X present tool.
•Inserts ran parts for 3+ days before needing changed.
Gray Cast Iron, class 30, 20 R/CGray Cast Iron, class 30, 20 R/C
GSN-100 Class 435 Gray Iron Turning
GSN-100 Class 435 Gray Iron Turning
The areas of focus for testing were:Tool #1 Back Face and Rough Pilot
Area of focus
Round 1 testingRound 1 testing
Customer target: 150 parts per edge
Tool #1 - Back Face and Rough Pilot
Round 1 testingRound 1 testing
Customer target: 150 parts per edge
Date: 16-Jan-12 Operator:Customer: Engineer:Machine: HONOR VL-86 Cell 2BCoolant: no
Present GreenleafOperation: back faceInsert Manufacturer sumitomoInsert: CNGX-434 CNGA-458Edge Prep: T2Grade: BNS800 GSN100Toolholder:
Insert Price ($): $88.00 $9.74 # edges/insert 4 4Price/ edge ($) $22.00 $2.44Passes/ edge 150 168Insert cost/ Pass $0.15 $0.01
Burden rate ($/hour) $60.00 $60.00Passes to finishing cut: 1.00 1.00
# of indexes/ pass 0 0Time to index (sec) 60 60Cost to index ($) $0.00 $0.00
Part Diameter (in.): 11.085 11.085speed (sfm) 3000 3000RPM (rev/min) 1034 1034DOC (in.) 0.2 0.2Feed (in/rev) 0.02 0.02LOC (in.) 4.611 4.611
removal rate (in3/min): 19.07 19.07Cut time for 1 pass(min): 0.22 0.22Cost to cut ($): $0.22 $0.22
Cost to cut 1 Pass: $0.37 $0.24Cost to complete all passes: $0.37 $0.24
Total cycle time (min): 0.22 0.22
Parts/Year 93,600Cost/Year $34,602.88 $22,231.53
Cost savings/year $12,371.36
Cost/day $2,587.82 $1,662.61Cost/week $12,939.11 $8,313.07Cost/year $672,833.83 $432,279.66
Total cost savings/year $240,554.17
Total manufacturing at 7000 Parts/day at 5 days per week
INSERT COST PER PART
BURDEN RATE COST OF PART
INSERT JUSTIFICATION FOR TURNING
based on 15 parts/hr, 3 shifts, 5 days a week, cell 2B
SFM VARIES DUE TO DIAMETER RANGEDIA. RANGE 8.779-13.39
The areas of focus for testing were:Tool #3 – Inboard Bottom Face.
Tool #6 – Finish Pilot
Tool #6
Tool #3
Round 2 testingRound 2 testing
Customer target: 300 parts per edge
Tool #3 – Inboard Bottom Face.
Round 2 testingRound 2 testing
Customer target: 300 parts per edge
Date: 13-Mar-12 Operator:Customer: Engineer:Machine: Merritech 15-30 VNC Cell 1Coolant: no
Present GreenleafOperation: bottom faceInsert Manufacturer sumitomo GreenleafInsert: SNGX-434 SNGN-454Edge Prep: T2Grade: BNS800 GSN100Toolholder:
Insert Price ($): $88.00 $9.74 # edges/insert 8 8Price/ edge ($) $11.00 $1.22Passes/ edge 300 400Insert cost/ Pass $0.037 $0.003
Burden rate ($/hour) $60.00 $60.00Passes to finishing cut: 1.00 1.00
# of indexes/ day @ 20 pcs/hr 1.6 1.2Time to index (sec) 60 60Cost to index ($) $0.07 $0.05
Part Diameter (in.): 13.14 13.14speed (sfm) 2800 2800RPM (rev/min) 814 814DOC (in.) 0.1 0.1Feed (in/rev) 0.018 0.018LOC (in.) 4.471 4.471
removal rate (in3/min): 6.55 6.55Cut time for 1 pass(min): 0.31 0.31Cost to cut ($): $0.31 $0.31
Cost to cut 1 Pass: $0.41 $0.36Cost to complete all passes: $0.41 $0.36
Total cycle time (min): 0.33 0.33
Parts/Year 124,800Cost/Year $50,980.89 $44,704.75
Savings/year @ 1 spindle $6,276.14
Savings/year @ 6 spindles $37,656.84
Savings/year @ 1 spindle $18,828.42
Savings/year @ 6 spindles $112,970.52
INSERT JUSTIFICATION FOR TURNING
Total manufacturing at 20 parts/hr, 3 shifts, 5 days a week on 3 machining centers
INSERT COST PER PART
BURDEN RATE COST OF PART
based on 20 parts/hr, 3 shifts, 5 days a week, cell 1
DIA. RANGE 8.779-13.25
RPM VARIES DUE TO DIAMETER RANGE
Tool #6 – Finish Pilot.
Customer target: 300 parts per edge
Round 2 testingRound 2 testing
Date: 13-Mar-12 Operator:Customer: Engineer:Machine: Merritech 15-30 VNC Cell 1Coolant: no
Present GreenleafOperation: finish pilotInsert Manufacturer sumitomo GreenleafInsert: CNGX-434 CNGN-454Edge Prep: T9Grade: BNS800 GSN100Toolholder:
Insert Price ($): $88.00 $9.74 # edges/insert 8 8Price/ edge ($) $11.00 $1.22Passes/ edge 300 400Insert cost/ Pass $0.037 $0.003
Burden rate ($/hour) $60.00 $60.00Passes to finishing cut: 1.00 1.00
# of indexes/ day @20 pcs/hr 1.6 1.2Time to index (sec) 60 60Cost to index ($) $0.07 $0.05
Part Diameter (in.): 8.779 8.779speed (sfm) 2500 2500RPM (rev/min) 1088 1088DOC (in.) 0.06 0.06Feed (in/rev) 0.016 0.016LOC (in.) 0.53 0.53
removal rate (in3/min): 0.55 0.55Cut time for 1 pass(min): 0.03 0.03Cost to cut ($): $0.03 $0.03
Cost to cut 1 Pass: $0.13 $0.08Cost to complete all passes: $0.13 $0.08
Total cycle time (min): 0.06 0.05
Parts/Year 124,800
Cost/Year $16,696.53 $10,420.39
Savings/year @ 1 spindle $6,276.14
Savings/year @ 6 spindles $37,656.84
Savings/year @ 1 spindle $18,828.42
Savings/year @ 6 spindles $112,970.52
INSERT JUSTIFICATION FOR TURNING
Total manufacturing at 20 parts/hr, 3 shifts, 5 days a week on 3 machining centers
INSERT COST PER PART
BURDEN RATE COST OF PART
based on 20 parts/hr, 3 shifts, 5 days a week, cell 1
GSN-100 Ductile Iron Turning
GSN-100 Ductile Iron Turning
65-45-12 Ductile Iron, 30 R/C65-45-12 Ductile Iron, 30 R/C
Greenleaf WG-6218-2AGSN-100
• 1350 SFM (412 M/Min)• .0065 IPT (0,17 mm/tooth)• Machining 75 grooves/insert
Prior: Greenleaf WG-6218-2A HSN-100
• 1350 SFM (412 M/Min)• .0065 IPT (0,17 mm/tooth)• Machining 15 grooves/insert
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®®
GSN-100 Cast Iron Milling
GSN-100 Cast Iron Milling
Gray Cast Iron, as cast
We are running:Milling Cutter- C404
Insert- CNGN-454 (CNGN120716)Two Nests are used so both the 80 and⁰ 100 corners of the Insert can be utilized⁰
Material – Gray Cast IronGrade- GSN-100 (GSN-100)DOC- .13- .19 (3.3- 4.8 mm)
Speed- 4,000- 5,000 SFM (1,220- 1,525 M/Min)
Feed- .0065-.0085 (.16- .22 mm) Fd/InsertCut time- approx. 80 minutes per Insert
index.A 3 reverse lead cartridge is used⁰
to circle interpolate Bores
GSN-100 Class 500 Gray Iron Milling
GSN-100 Class 500 Gray Iron Milling
Class 500 Gray Iron as castClass 500 Gray Iron as cast
Prior: Seco carbide APKT 16 MM Insert
• 625 SFM (190 M/Min)• .005 IPT (0,13 mm/tooth)• 11 Minutes cut time
• Greenleaf SNGN-434 (SNGN-120416) T2 GSN-100 • 3” Diameter C4 cutter
• 4000 SFM (1220 M/Min)• .005 IPT (0,13 mm/tooth)• 3 Minutes cut time
Ball Screw Housing
®®
GSN-100 Ductile Iron Milling
GSN-100 Ductile Iron Milling
Objective: To prove out GSN-100 as a replacement for HSN-200 in Ductile Iron Milling
Objective: To prove out GSN-100 as a replacement for HSN-200 in Ductile Iron Milling
• Material – Ductile Cast Iron:• Grade – HSN-200• DOC – .06” (1.52 mm) x 3 passes• Speed – 3000 SFM (915 M/Min)• Feed – .0045” (.11 mm) Actual Chip
thickness• Cutting time – 13.5 minutes• Parts – 90
• Material – Ductile Cast Iron:
• Grade – GSN-100
• DOC – .06” (1.52 mm) x 3 passes
• Speed – 3000 SFM (915 M/Min)
• Feed – .0045” (.11 mm) Actual Chip thickness
• Cutting time – 13.5 minutes
• Parts – 90
We are running:
Milling Cutter – CP-403R
Nest – XFNPS-8043
Insert – SPGN-434 T2A (SPGN120416)
GSN-100 DuctileGGG-50 Milling
GSN-100 DuctileGGG-50 Milling
GGG-50 Milling 290-350 BHNGGG-50 Milling 290-350 BHN
Other GSN-100Applications
Other GSN-100Applications
GSN-100 Jethete M152 Milling
GSN-100 Jethete M152 Milling
A 82% iron, 12% chromium material classified as a Martensitic Stainless Steel which has high
tensile strength and sufficient ductility at elevated temperatures as well as high corrosion
resistance. The material is very sensitive to heat during the machining process which
makes the material rapidly work harden. The application of Jethete M152 is mainly in high
stress gas turbine parts.
Jethete M152Jethete M152
Jethete M152 32-36 R/CJethete M152 32-36 R/C
Cutter: WSRP-60002 RH
Insert: RPGN-43 T1A HSN-200
Speed: 1500 SFM (458 M/Min)
Feed: .0033 IPT (.08 MM/tooth)
DOC: .050” (1.27 MM)
WOC: 2” (51 MM)
3 ½-4 minutes cut time, inserts showing flank wear, and experiencing heat in part
3 ½-4 minutes cut time, inserts showing flank wear, and experiencing heat in part
Jethete M152 32-36 R/CJethete M152 32-36 R/C
Cutter: WSRP-6001.2 RH
Insert: RPGN-43 T1A HSN-200
Speed: 1600 SFM (488 M/Min)
Feed: .0015 IPT (.04 MM/tooth)
DOC: .050” (1.27 MM)
WOC: 1.25” (31.8 MM)
4 minutes tool life, 37 % increase in feed over HSN-200’s best run!
4 minutes tool life, 37 % increase in feed over HSN-200’s best run!
Jethete M152 32-36 R/CJethete M152 32-36 R/C
Cutter: WSRP-6001.5 RH
Insert: RPGN-43 T1A GSN-100
Speed: 1600 SFM (488 M/Min)
Feed: .0028 IPT (.07 MM/tooth)
DOC: .050” (1.27 MM)
WOC: 1.5” (38.1 MM)
GSN-100 HRSA MillingGSN-100 HRSA Milling
GSN-100 42 R/C Age Hardened WaspaloyGSN-100 42 R/C Age Hardened Waspaloy
42 R/C age hardened Waspaloy42 R/C age hardened Waspaloy Cutters Inserts
FMRN-050R
FMRN-063R RNGN-45
FMRN-080R T2A
FMRN-100R
FMRP-5040R RPGN-43
FMRP-6340R T2A
From running all the tests it is apparent that we have a safe secure process with all sizes of cutters (both negative and positive) running at a feed rate of 0.0027”-0.0029”, (0.07mm-0.075mm) tooth. The surface speed is dependent on width of cut. (3000-3600 SFM/915-1100 SMM range)
GSN-100Stocking Program
GSN-100Stocking Program
GSN-100 Stocking ProgramGSN-100 Stocking Program
SNGN-433 T1A
SNGN-433 T2
SNGN-433 T2A
SNGN-434 T1A
SNGN-434 T2
SNGN-453 T2
SNGN-454 T2
SPGN-322 T1A
SPGN-434 T2A
TPGN-322 T2A
WG-6250-2A
WNGA-433 T2
ACHN-3222 T1A
ACHN-3422 T1A
CNGA-432 T2
CNGA-432 T2A
CNGA-433 T2
CNGA-434 T2
CNGA-434 T3A
CNGA-453 T2
CNGA-454 T2
CNGN-432 T2
CNGN-433 T2
CNGN-433 T9
CNGN-434 T2
CNGN-434 T2A
CNGN-453 T1A
CNGN-453 T2
CNGN-454 T1A
CNGN-454 T2
CNGN-454 T2A
CPGN-433 T2A
DNGA-432 T2
DNGA-433 T2
RPGN-2.52 T1
RPGN-2V T2
RPGN-32 T1
RPGN-3V T1A
RPGN-3V T2
RPGN-43 T1
RPGN-43 T1A
RPGN-43 T2A
RPGN-4V T2
SNGA-433 T2
SNGA-434 T2
SNGA-454 T2
RCGN-3V T1
RCGN-4V T1
RNGN-43 T2
RNGN-45 T1
RNGN-45 T1A
RNGN-45 T2
RNGN-45 T2A
RNGN-45A
ReviewReview
• Silicon Nitrides have their place in the high speed ceramic machining market.
•Grades such as Greenleaf GSN-100 work well in interrupted cutting and Milling operations due to Silicon Nitrides high thermal
shock resistance.
• Greenleaf GSN-100 works well in the machining of Gray, Ductile, and Nodular cast irons.
• Although developed for Cast Iron machining, Greenleaf GSN-100 works on other materials such as selected high temp alloys.
• You will want to start gearing your HSN customers to the new Greenleaf GSN-100.
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Questions?Questions?
Thank You!
Thank You!