New Directions in

Cutting Tool Materials

1 Customers 97 © ISCAR All rights reserved 1997 (Grades) NEW LINE

 Application Range of Cermet,
Uncoated and Coated Carbide Grades

PCD
Cermet
Coated Carbide

CBN

ISO P.K.M. Uncoated Carbide

Toughness f Feed

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 Estimated Worldwide Consumption
of Cutting Tool Materials

1990 1995 2000

52%
50%
47% 48%
45%
40%
Carbide Grades

Carbide Grades

Carbide Grades
Others
Others

Others
HSS

HSS

HSS
8%
5%
3%

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 The ISO 513 Tool Material Range
P 01 Steel, steel casting

Ferrous
P 10 Steel, steel casting

metals Steel, steel casting

resistanc
Toughness
Increasing

Increasing
P 20
P Malleable cast iron

Wear
Speed
with

Feed
Steel, steel casting
long P 30 Malleable cast iron
chips Steel,
P 40 steel casting with
cavities
Steel,
P 50 steel casting with
cavities
Steel, steel casting, manganese steel
Ferrous M 10 Grey cast iron, alloy cast iron
metals
Steel, steel casting, austenetic or

Toughness
with long

Increasing

Increasing
M 20

resistanc
manganese steel, Grey cast iron,
M

Speed
or short

Wear
Feed
chips, and Steel, steel casting, austenetic steel, Cast
non-ferrous M 30 iron, high temperature resistant alloy
metals Mild free cutting steel, low tensile steel
M 40 Non-ferrous metals and light alloys
Very hard grey cast iron, chilled
Ferrous K 01 casting, high silicon aluminium alloys, hardened steel
metals
with short Grey cast iron, malleable cast iron,
K 10 hardened steel, silicon aluminium alloys, copper alloy

Increasing

Increasing
chips,

Toughness
K

Speed

resistanc
non-ferrous

Feed
Grey cast iron, Non-ferrous

Wear
metals K 20 metals: copper, brass, aluminium
and Low hardness Grey cast iron
non-metalic K 30 low tensile, compressed wood
materials
Soft wood or hard wood
K 40 Non-ferrous metals

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 Iscar Grades Based on ISO 513

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 Iscar Cutting Grades
According
to Product Family

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 Uncoated Carbide Grades:
Composition and Properties
Toughness

Hot Hardness Wear Resistance

(Magnetic Saturation)
P40 M40
300
CO-Content

mT M30
P30 K30
250 M20
P10 P20 P25 K20
150
M10 K10
100 K01
75
10.0 11.0 12.0 13.0 14.0 g/cm3 15.5
10.5 11.5 12.5 13.5 14.5
TiC, TaC Specific Weight

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 Uncoated Carbides -
Substrates for Coating
10 mm
(X 2000)

IC21,Coarse WC IC28, Fine WC IC50M, Fine WC

8% Co with Multi-Carbide with Multi-Carbide
(TaC, NbC) (TiC, TaC, NbC)
12.5% Co 11% Co

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 Uncoated Carbides -
Substrate Properties
DENSITY HARDNESS FRACTURE TRANSVERSE
GRADE gr/cm3 HV 20KG TOUGHNESS RUPTURE
kg/mm 2 K1C STRENGTH
0.5
MPa (TRS)
PSI X1000
IC 07 14.93 1745 11.3 520
IC 08 14.49 1580 14.8 610
IC 21 14.70 1270 19.5 450
IC 28 14.26 1340 18.0 510
IC 10 14.70 1480 13.9 450
IC 50M 12.45 1480 13.4 360
IC 20 14.96 1640 11.1 350
IC 30N 6.93 1380 10.2 260

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 Thermal Conductivity
as a Function of Temperature
50
TiC Hardness HV20°
W
2500
m°k TaC
40

NbC
Thermal Conductivity

30
TiN 2000

20

10

Al2O3 2200
0 500 1000 1500
Temperature - °C

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 PVD and CVD: Pressure-
Temperature Zones During Coating

105 MT-CVD
CVD

104
103
102
101
P 100
10-1 PVD
10-2
400 600 800 1000 1200 °C
T
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 Main Features
of PVD and CVD Coating
Process Chemical Vapor Physical Vapor
Deposition-(CVD) Deposition-(PVD)
Temperature 800° - 1100° C 200° - 500°
Coating Layers Carbides, Nitrides TiN,
Oxides TiCN, TiAlN
Total Layer Thickness 2 - 15 mm 2 - 5 mm
Features and • Coated on all sides • More oriented coating
Properties • More layer • Sharp cutting edge
combinations • Partial Adherence
possible • Less stress between
• Good coating substrate and
adherence coating

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 Cutting Tool Material Strength
of PVD and CVD Coatings

(TRS)

(TRS)
Transverse Raptnre Stregth

(-10:0%) (-10%)

Un coated
(-30%)

CVD-Low Temp.
CVD

PVD
5 10 15 um
Coating Thickness

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 General Stress Distribution
in PVD and CVD Coatings
CVD Coating (5-10mm) PVD Coating (2-6mm)

Substrate Substrate
Tensile Stress

Tensile Stress
Depth (mm) Depth (mm)
5 10 5 10
Compression Stress

Compression Stress

Coating Substrate Coating Substrate

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 CVD Coatings
First and Second Generations

First Generation (1970)

Titanium Carbide Coating

Second Generation (1980)

Multi-layer Coating

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 Layers of CVD Coated Grades
Second Generation

Example: Iscar IC 656, IC 635

TiN 8+2mm

TiCN
TiC
Substrate P40

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 CVD Coated Carbide Grades
for Turning in the 1990s
IC 8025 and IC 8048
Improved toughness achieved by a cobalt-enriched
layer of the substrate
3rd Generation 4th Generation 3rd Generation 4th Generation

IC 848 IC 8048 IC 825 IC 8025

TiN
Al2O3

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 Comparison of Crater Wear on Uncoated
and CVD Coated Inserts in Turning
Machining Conditions:
Workpiece: C60 (1060)
Insert: SNUN 120408 (432)
Vc: 200 m/min (656 SFM) ISO M15 Uncoated
Cutting time: 2 min
ap: 1.5 mm (.06”)
f: 0.28 mm/rev (.011”/rev)

TiC Coated TiC+Ti(C,N)+TiN Coated

Cutting time: 10 min Cutting time: 10 min

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 Basic CVD and PVD Coating
Layers of Iscar Inserts
COLOR CODE

Al 2O3
TiC
TiCN
TiN IC450 X5000 (5 m m) IC328 X5000 ( 2 m m)
CVD PVD
10 m m

IC418 IC450 IC520M IC635 IC220 IC328

IC428 IC418 IC656 IC228 IC350
IC428 IC250 IC3028
Turn Mill
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 PVD Grades with TiCN as Upper Layer

IC 328, IC 3028, IC 350

TiCN 2-4µm

TiN
1-2µm

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 PVD Grades with TiN as Upper Layer
IC 220, IC 228, IC 250
For Milling and Threading

TiN 6+2mm

TiCN
TiN
Substrate

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 IC 9025 and IC 9015 Structure
and Properties of Basic CVD Layers
TiN
Al2O3
TiCN
TiN
Substrate

Substrate: High toughness

TiN: Low friction, resistance to BUE
Al2O3: Heat barrier, low heat conductivity
TiCN: Resistance to flank wear
TiC: High hardness
25 Customers 97 © ISCAR All rights reserved 1997 (Grades) NEW LINE
 IC 9015 New Low Temp. CVD Grade
Higher hardness, good wear resistance
Range: ISO P10-P30, K10-K25
Applications: Finishing, semi-finishing,
carbon steel, alloy steel, cast iron,high cutting speed
Competitors:
GC4015 - Sandvik
TX150, KC9010 - Kennametal
TX150, TP100 - Seco

TiN 10mm
Al2O3
TiCN
TiN
Substrate P25

26 Customers 97 © ISCAR All rights reserved 1997 (Grades) NEW LINE

 New Low Temperature
CVD Coated Grade IC 9025
Improved toughness achieved by a cobalt-enriched
layer of the substrate
High wear resistance
ISO range: ISO P20-P30, M15-M30
Applications: Roughing and semi-roughing,
carbon steel, alloy steel, stainlees steel
Competitors:
GC2015,GC4025, LC25 - Sandvik
6025 Mitsubishi
AC2000 - Sumitomo TiN 10mm
TP200 - Seco
Al2O3
6025- Mizubishi
TiCN
TiN
Substrate P30
27 Customers 97 © ISCAR All rights reserved 1997 (Grades) NEW LINE
 IC 9015 Wear Behavior of CVD Coated
Workpiece: SAE 1045
Insert: CNMG 1200408GN
Vc: 320 m/min (1050 SFM)
ap: 2 mm (.079)
Top view of crater wear
f: 0.25 mm/rev (.010)
T: 12 min.
Side-cutting-edge wear

Radius wear

28 Customers 97 © ISCAR All rights reserved 1997 (Grades) NEW LINE

 The New IC 07 and PVD Coated IC 507
Grades for Turning
Substrate: 6%Co, Cr2C3,WC
Coating: TiCN+TiN 3±1mm
Applications:
High-temp. alloys
Stainless steel
Micro-stracture of IC 07
Hard coating
Impact resistance

TiN

TiCN

Micro-stracture of IC 20 PVD coated IC 507

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 Cutting Tool Materials
for ISO Turning in 1995 and 1996

1995 1996

79% 80%
CVD 3%
4% Cermet Cermet CVD
Coated Coated
Uncoated
Uncoated

PVD 14% PVD

16%

1% 3%

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 Cermet: Composition and Grades

Ceramic Binder Iscar Grade

TiC Ni (1970s)
TiC Ni + Mo or Mo2C IC60T, 80T, 100T

TiCN Ni + Mo or Mo2C (1990s)

TiCN + TaxNbyC Ni + Mo or Mo2C + Co IC30N, 20N

(1995)
Cermet + PVD TiN Coating IC530N, 520N

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 Cermet:
Comparison with WC-TiC-Co Grades
PROPERTIES APPLICATIONS
Higher hardness Higher cutting speeds
Higher hot hardness Finish turning
Lower friction Better surface finish
Minimal BUE Small and medium
Better wear resistance chip loads
Lower toughness (TRS) Mainly continuous
Chipping more likely cutting

Lower modulus of elasticity

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 Surface Finish
with Various Tool Materials in Turning
Machining Data:
Vc: 250 m/min (820 sfm)
f: 0.30 mm/rev (.012”/rev) Surface Finish, Rt (µm)
1.00
ap: 3.0 mm (.118”)
Workpiece: SAE 1045 0.75

Dry, No coolant.
0.50

0.25

0
Cermet Coated Carbide
Carbide

35 Customers 97 © ISCAR All rights reserved 1997 (Grades) NEW LINE

 Iscar Cermet Grades
IC30N (ISO P10-P30), IC20N (ISO P05-P25)
Provides excellent resistance to BUE,
wear and plastic deformation even at high
cutting speeds and medium feeds.

Useful for semi-finishing and finishing operations.

Recommended for parting, grooving, multi-function

operations and finish milling with good wear
resistance and reasonable cutting-edge
strength.

IC530N (ISO P10-P30), IC520N (ISO P05-P25)

Recommended for turning in the finishing and semi-
finishing range with improved tool life
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 Milling Grades - ISO Chart

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 Impact Resistance of PVD and CVD
Coated Grades in Interrupted Turning

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 Tool Life in Milling with IC520M
Source: Customer in Sweden

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 Milling with IC 328-PVD Coated Grade

Workpiece Materials: Machining Conditions:

Austenitic stainless steel Interrupted cuts
Martenistic stainless steel High impacts
Exotics Medium-to-low cutting
Titanium-base alloys speeds
Nickel-base alloys Higher feeds
Mold steel Negative and positive
General use geometry
s

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 IC 328 - Comparison with Other Grades
Vc : 80m/min (260 sfm)
Workpiece: SAE 316L (Stainless Steel)
VBH Š 0.3 mm (.012”) wear land
Flushing: Emulsion APKT1003PDR-HM
fz: 0.1mm/t (.004 in/tooth) ADKT1505PDR-HM

16.0
MACHINING TIME (min)

14.0
12.0
10.0
8.0
6.0
4.0
2.0
0.0
IC635 IC630 IC228 IC328

41 Customers 97 © ISCAR All rights reserved 1997 (Grades) NEW LINE

 IC 328 for Milling Stainless Steel
SEKN 1203 AFN
Vc : 120m/min (400 sfm)
fz : 0.12mm/t (.005 inch / tooth)
Workpiece: SAE 316L
Flushing: Emulsion
16.0
MACHINING TIME (min)

14.0
12.0
10.0
8.0
6.0
4.0
2.0
0.0
IC328 KC720 EXP 1 EXP 2 WTA51 WTL71 EXP 3 EXP 4

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 IC 328 for Improved Tool Life
when Milling Steel

Tool life

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 Cost Reduction with IC 328 on 316L

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 Tool Life Improvement
IC 328 on Inconel 625

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 The Advantage of PVD in Milling
with Low to Medium Cutting Speeds
Workpiece: SAE 1060

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 The Advantage of CVD in Milling
with High to Medium Cutting Speeds
Workpiece: SAE 1060

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 CVD Grades IC 450, IC 418
with Ceramic Coating
Application Range

IC 450, IC 418

1. GGG60
1. GGG60
2. SAE1060
2. GG20
3. AISI 316L + coolant

1997: IC 910

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 IC 450 / IC 418 Thin Layer CVD for Milling

COLOR CODE
Al 2O3
TiC
TiCN
TiN
IC450 X5000 (5 µm)
CVD
10 m m

5 mm
IC450 EXP A EXP B EXP C ... IC450
IC418 IC418
Turn Mill

50 Customers 97 © ISCAR All rights reserved 1997 (Grades) NEW LINE

IC 418 and IC 450 on Spheroidal Cast Iron
Insert: ADKT 1505PDTR-42
Vc : 220 m/min (725 sfm)
fz : 0.2 mm/t (.008 inch/tooth)
Workpiece : GGG60

0.4 Machining time:

(.015”) T=20 min
Wear (mm)

0.3
(.012”) T=10 min
0.2
(.007”)
0.1
(.004”)
0.0
IC418 IC418 IC450 IC450
Turn Mill Turn Mill

51 Customers 97 © ISCAR All rights reserved 1997 (Grades) NEW LINE

IC 450 and IC 328 Austenitic Stainless 316L
Insert: ADKT 1505PDR-HM
Vc: 120m/min (400 sfm)
fz: 0.12mm/z (.005 inch/z)
Workpiece: SAE 316L + coolant
Tool life criteria: Until 30% load increase
20.0 Cutter:
MACHINING TIME (min)

F45AD-D50-22
16.0

12.0

8.0

4.0

0.0
IC450 Turn IC450 Mill IC328
52 Customers 97 © ISCAR All rights reserved 1997 (Grades) NEW LINE
 Cost Reduction in Milling with IC 450

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Case Story: IC 328 on Tool Steel with Heliball

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 The Advantage of IC 418 in Milling
Machining conditions
Insert: SDMT 1205HQ
Cutter: F90SD-D100

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 Selection Guide by Workpiece Material
Preferences
Workpiece Material 1997

IC950

IC950

IC910

IC910

IC908

Mold IC950

IC908

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 First Stage
Towards the Year 2000

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