Contents

GC2030/2040
ISO

Speed up stainless steel milling with new long life inserts and improve your productivity
Two new insert grades GC2030 and GC2040 in dedicated geometries -ML & -MM break the rules in stainless steel milling and move the performance levels to that which had previously been restricted to steel milling.

Both grades are developed mainly for dry milling at cutting speeds someway above the critical area where the destructive built up edges appear. With micro geometries carefully adapted to the insert type and the application area of each grade the most common problems in milling austenitic, ferritic/martensitic, Duplex and PH steels are reduced dramatically.

The tendencies for smearing, built up edges and bad heat conduction within this material group, have, by tradition, been controlled by applying cutting fluid at a low cutting speed resulting in short tool life and a low production rate. The new grades are introduced in inserts for CoroMill cutters and some ISO facemills.

GC2030 and GC2040 in combination with two light cutting geometries provide the optimum performance for each type of operation.
The extra positive and sharp ML-geometry PVDcoated GC2030 Finish milling Small depth of cut/small feed/tooth The positive and allround MM-geometry Rough milling Rolled and forged austenitic materials Duplex stainless steels

MT-CVD -coated GC2040

PH steel

Rough milling Cast materials Ferritic/Martensitic Ti-stabilized austenitic materials

82

CoroKey inserts

carbide grades with dedicated geometries

For each of the new inserts the carbide grade and a unique geometry is combined. GC2030 as well as GC2040 are introduced in two geometries for CoroMill 245, CoroMill 290 and CoroMill 390 individually adapted to the application area of each grade and type of insert. Good visual surface finish and minimal burr formation is often the criteria when choosing inserts for ISO M milling. Both the positive all round "MM-geometry" the first choice for medium operations and the extra positive "ML-geometry" favourable in operations requiring a lighter cut meet these demands.

ML

MM

Long life performance at high cutting speeds The carbide substrates and the coatings of GC2030/GC2040 are composed for best performance in dry milling at high cutting speeds way above the unfavourable built up edge (BUE) area. At these speeds the use of cutting fluid accelerates the growth of thermal cracks, caused by large differences in edge temperatures, which quickly reduce the edge security and tool life.
BUE

vc

We strongly recommend, therefore, to always rough mill the component in a dry condition. For a limited number of operations, the surface finish demands cannot, however, be fully coped with without use of cutting fluid.

()

Application area GC2030 and GC2040 together cover a wide application area from ISO M15 to M40 partly overlapping each other making it easier to optimize the choice. With the complementary grades CT530, GC4040, GC1025 (and for some styles of inserts GC235) the M-line in milling is complete.

M
STAINLESS STEEL

10

GC 1025 CT 530 GC 2030

20

30

GC 2040 GC 235

X
GC 4040

40

The PVD-coated GC2030 (M15 M35) A fine grain substrate with a thin PVD layer for good properties in sticky materials. for milling austenitic and duplex stainless steels.
GC2030 TiN TiAIN Substrate TiN Al203 Ti(C,N) GC2040 Substrate

The MT-CVD-coated GC2040 (M20 M40) A tough substrate with a thin coating and resistant to abrasive wear. for ferritic/martensitic stainless steels, Ti stabilized austenitic stainless steel and PH steels.

83

GC2030 Both productivity and tool life GC2030

Productivity increase by high speed

GC2030/MM

Alternative grades for longer tool GC2030/MM (GC2040)/MM life

Material: Austenitic/ferritic stainless steel, (Duplex) (CMC 05.51) (SS 2324) Cutter: CoroMill 245, Dc = 80, z = 6 Insert: R245-12 T3 M-MM, grade GC2030 (GC2040) Machine: Heckert, VMC ap/ae = 5,5/40 mm (4+3/40 mm) vc = 226 m/min vf = 630 mm/min fz = 0,12 mm/tooth
ISO

Material: Austenitic stainless steel (CMC 05.21) HB 180 Cutter: CoroMill 245, Dc = 160, z = 10 Insert: R245-12 T3 M-MM, grade GC2030 Machine: VM/ISO 50 ap/ae = 3/140 mm vc = 210 m/min fz = 0,24 mm/tooth vf = 1000 mm/min
ISO

40

1500 800 3 156 Comments: A "bottle neck" in the production could be removed, as feed rate was doubled, and contradictory the tool life was also doubled. Comments: An operation within the application area where GC2030 and GC2040 overlap each other. Both grades provided an improved tool life of about four times GC2030 somewhat longer. GC2040 on the other hand, could use a higher feed per tooth (0,15 mm) providing a feed rate increase of 27%.

Productivity increase by high speed GC2030/MM

Material: Austenitic stainless steel (CMC 05.21) (1.4301) Cutter: CoroMill 290, Dc = 63, z = 6 Insert: R290-12 T3 08M/E, grade GC2030 Machine: Stenel FFZ 200 /HSK 63 ap/ae = 3-7/26-38,5 mm vc = 220 m/min fz = 0,14 mm/tooth vf = 925 mm/min
ISO

Dry milling for productivity and long tool life

GC2030/MM

Material: Austenitic stainless steel (CMC 05.21) Cutter: CoroMill 390, Dc = 25, z = 2 Insert: R390-11 T3 08M-MM, grade GC2030 Machine: V.MC / ISO 40 / 15 KW ap/ae = 10/12 mm vc = 200 m/min fz = 0,1 mm/tooth vf = 510 mm/min
ISO

3-7

M
10

12

Comments: The feed rate was increased 50% and the tool life maintained.

Comments: An operation where "dry milling at high speed" outperformed "wet milling at low speeds" by both productivity (+ 67%) and tool life (five times).

84

Contents

GC2040 Long tool life under varying conditions GC2040

High edge temperature for extended tool life

GC2040/ML

Tool life increase by a dedicated geometry

Material:(CMC 05.22) 17/4 PH HRC 35-40 Cutter: CoroMill 390, Dc = 20, z = 2 Insert: R390-11 T3 08M-ML, grade GC2040 Machine: Fadal VMC 3016 ap/ae = 4-5/13-20 mm vc = 80 m/min fz = 0,1 mm/tooth vf = 254 mm/min
ISO

GC2040/ML

Material: Austenitic stainless steel (CMC 05.22) (Corrax) Hardened HB330 Cutter: CoroMill 245, Dc = 80, z = 6 Insert: R245-12 T3 E-ML, grade GC2040 Machine: Modig MD 7200 VF/ HSK 63 ap/ae = 2/67 mm vc = 129 m/min fz = 0,17 mm/tooth vf = 523 mm/min
ISO

M
2

4-5

500 200 Comments: High material hardness gave the right level of edge temperature for extended tool life +67%! Comments: The choice of geometry decisive of the tool life in difficult to machine PH-materials. A positive L geometry edge of sufficient toughness improved the result compared to the -MM geometry 15 times!

Tool life more than doubled

GC2040/MM

The new grade improved tool life

GC2040

Material: Austenitic stainless steel (CMC 05.21) (SS 2343-02) Cutter: CoroMill 245, Dc = 80, z = 6 Insert: R245-12 T3 M-MM, grade GC2040 Machine: Okuma MC-5VA/ISO 50 ap/ae = 4/50-65 mm vc = 200 m/min fz = 0,17 mm/tooth vf = 800 mm/min
ISO

Material: Ferritic/martensitic stainless steel (CMC 05.11) (X12CrNiMo12) Cutter: Competitor, Dc = 80, z = 5 Insert: SEKN 1504 AZ, grade GC2040 Machine: Heller/SK 50 ap/ae = 7-10/45-78 mm vc = 170 m/min fz = 0,19 mm/tooth vf = 656 mm/min
ISO

M
10
7

78

516

Comments: Tool life improved from two to five components/set of edges with the feed rate maintained.

Comments: In a comparison of ISO inserts with equal geometries, just the change of grade improved tool life 42%.

85