KENNAMETAL has released three turning guides that provide application information as well as a catalogue of turning inserts and grades.
The three turning guides are an 80-page book covering steel materials, a 100-page guide covering cast iron materials, and a 100-page guide covering high-temperature alloys. The guides are based on the Kenna Perfect insert selection system. This is designed to aid in choosing the optimum insert geometry, grade, and cutting conditions. The guides extend beyond the selection information provided in Kennametal catalogues by providing more detailed charts, making it possible to optimise productivity for less common materials. The recommendations in the book are based on customer applications, tool tests, and chip control studies. The book is digest-size, making it easy to store and use in the production environment. Kennametal plans to issue two more turning guides, covering stainless steels and universal materials.
Using the Kenna Perfect method, users select the material from a range of choices. Then they select the insert geometry based on the depth of cut and feed rate, using charts provided in the book. For example, in steel turning, four insert geometries are presented and the chart shows the depth of cut and feed rate ranges that are handled by each. The next step is selecting the grade based on four possible cutting conditions. These are heavily interrupted cut, lightly interrupted cut, varying depth of cut, and smooth cut. The final step is selecting the cutting speed based on another set of charts that provide a number of material choices. For steel machining, the alternatives include low carbon and free-machining steels, medium and high carbon steels, alloy and tool steels below 35 HRC, alloy and tool steels above 35 HRC, and ferritic, martensitic, and PH stainless steels.
The turning guides also include metallurgical information that will aid in material identification. For example, the steel turning guide explains how steels are classified based on their composition, finishing methods, and product form. The systems for classifying carbon and alloy steels were developed by the American Iron and Steel Institute (AISI) and the Society of Automotive Engineers (SAE). The expert application advisor provides solutions to common tool application problems. For example, when chip control is a problem, the steel guide suggests using a different insert geometry, increasing feed rate, changing the lead angle, using a smaller nose radius, or using high-pressure coolant. The guides also provide a wide range of tool tips. For example, one tool tip in the steel turning guide points out that using wiper inserts allows feed rates to be doubled while maintaining the required surface finish.