Cast iron processing new world

When it comes to cast iron, people immediately think of the word "easy to process." However, today's cast iron materials have great processing properties, and the processing requirements are not the same, which brings new challenges to machining.

The lead angle of the new milling cutter CoroMill 365 has been increased from 45° to 65°

The true 8-blade insert also introduces cutting forces into the base support of the insert for added stability and durability

Different needs


Traditional cast iron is divided into gray cast iron, ductile iron and white cast iron, which are suitable for different applications due to their specific properties. With the development of materials, the cast iron family has now added a combination of compacted graphite iron (CGI), austempered ductile iron (ADI) and a series of alloy cast irons, which has also brought new challenges to machining. These materials are widely used in the automotive industry, especially in the field of engine manufacturing. Because this type of application often requires more powerful component materials to cope with higher temperatures and better mechanical properties.
Cast iron is defined by the carbon content and is higher than the carbon content of steel. This carbon element is mostly present in the form of graphite and alloying elements, which helps to stabilize the structure of the material. Cast iron is abrasive during processing and its processing properties depend on the morphology of the graphite. In gray cast iron, the graphite content is mainly in the form of flakes, which is abrasive, but easy to cut into small chips; in ductile iron, graphite exists in a spherical shape, which is difficult to cut and has long chips; in vermicular graphite cast iron, Graphite exists in the form of connected worms and is difficult to process.

In the development of a new generation of inserts for cast iron milling, especially in CoroMill milling applications, grades and geometries are the key to improvement . A challenge in milling grey cast iron is how to minimize workpiece breakage. That is, the wear on the edge of the part. When cutting ductile iron, how to eliminate the impact of burrs is a problem to be solved. The main challenge in milling vermicular cast iron is how to reduce tool wear and the effects of burr formation.

New tools came into being


Although the materials used can cause different wear conditions, the tools must have a stable service life with high cutting parameters. Minimize component chipping and burrs during milling. In this context, Sandvik Coromant's new generation of cast iron machining blades and milling cutters have surpassed previous compromises.
  1. Different processing conditions

  2. During the development of the tool, consideration was given to the use and non-use of coolant. Wet milling involves cast iron dust, but it also limits the possibility of workpiece warping. In milling, dry machining is generally preferred and preferable for minimizing temperature fluctuations in the cutting edge. Because the temperature variation of the cutting edge can cause the blade to crack and chip. The coolant enhances the heat and can easily cause wear of various types of mixing, mainly thermal cracking.
  3. Suitable for different cutting edges

  4. In the development of a new generation of inserts for cast iron milling, especially in CoroMill milling applications, grades and geometries are the key to improvement. The goal to be achieved is achieved by increasing cutting parameters, extending predictable tool life and increasing the reliability of the cutting edge. From the point of view of use value, it is directly transformed into production efficiency by shortening the cycle, reducing the number of downtimes, improving the planned shutdown schedule of the equipment, and improving the processing safety.
    Dry processing of grey cast iron requires a thick hard coating. Here, only the chemical coating has sufficient heat resistance and wear resistance to achieve satisfactory tool life and surface integrity. The best performance is achieved with a modern, stress-free thick coating (a few times thicker than the physical coating) with the appropriate insert geometry. The new chemically coated grade GC3220 is optimized for dry milling of grey cast iron with CoroMill milling cutters.
    Wet milling can cause changes in the blade temperature, and different solutions are required to achieve optimum processing results. Thin and tough physical coatings are best suited for thermal cracking. For all types of cast iron milling (including dry and wet milling, except for dry milling of grey cast iron), this coating is also the most suitable solution. GC1020 has a physical coating of titanium aluminum nitride that provides the necessary balance between a harder blade substrate and the toughness required to handle different process properties. This grade will also add to the growing use of compacted graphite iron.

Heavy-duty cutting performance is not reduced


The processing of small-volume cast iron parts and automotive manufacturing are continually moving toward machining centers (including linkage equipment and single equipment), with approximately 80% of milling cutter diameters ranging from 63 to 160 mm. The roughing to medium milling of cast iron is carried out under severe and uneven conditions and is subject to strict cost constraints. From small light-duty cutting in small machining centers to heavy-duty mass production of powerful and stable equipment, processing conditions vary.
One of the benchmarks in the development of new milling cutters for roughing applications is the machining of successful CoroMill245 face milling cutters in heavy duty applications. R&D goals include improvements in bench feed, cutting forces, workpiece chipping, burr formation, surface finish and noise levels.
The lead angle of the new CoroMill 365 cutter has been increased from 45° to 65°, which brings many benefits to the machining, such as closer to the workpiece holder during machining. To counteract the increased chipping effect due to increased radial cutting forces, the insert geometry is designed to allow the tool to break away from cutting in a more advantageous manner. The true 8-blade insert also introduces cutting forces into the base support of the blade for added stability and durability. This brings a new way to minimize processing costs, increase reliability and increase productivity.

CoroMill 290 and GC3220 blades

CoroMill 245 and GC1020 blades

Following the latest steps in steel milling, Sandvik Coromant has made new progress in the field of cast iron by using high-grade grades that continuously improve toughness and wear resistance. In this competitive arena, the GC1020 and GC3220 are the latest innovations to achieve outstanding results.
Grade GC1020 - Sandvik Coromant's excellent all-steel cast iron milling inserts are the new choice for ductile iron and all wet cast iron machining. The rugged PVD coating guarantees high cutting speeds and reduced wear. It is a powerful tool for unstable conditions and is the new choice for CoroMill 390 milling cutters.
With the ultra-thick protective coating of the milling inserts, the GC3220 offers a significant increase in durability and wear resistance, greatly optimizing the dry cutting of grey cast iron. The GC3220 is designed for shoulder and face milling using the CoroMill range of cutters, especially for large diameter tools, providing smooth and reliable cutting performance.
These two grades enhance the existing geometry and offer CoroMill a wide range of blade options, increasing the productivity of cast iron milling for a variety of processes depending on the characteristics of the cast iron milling field.

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