Sandvik Coromant’s new steel turning insert grade helps THK Rhythm take

Inconel 718 (NiCr19FeNbMo DIN), 36-39 HRC, Continuous Cut, Flood Coolant. Cutting Conditions: 61m/min (200 sfm) , 0,25mm/rpm (0.0096 ipr), 1,5mm doc (0.06” doc)

KCS10B overcomes the most common challenges encountered in turning superalloys - cratering and depth-of-cut notching - two wear modes that often lead to unexpected and even catastrophic tool failure.

The seal system is designed to provide optimal configuration and a specially formulated extreme pressure synthetic lubricant that extends the bearing life. Specially formulated tungsten carbide hard facing is applied to all surfaces of the steel tooth cutting structure as well as on the shirttail tip and leading edge on all TCI (tungsten carbide insert) and steel tooth premium bits to provide extra protection in challenging formations. For additional security, flat top TCIs are pressed into the gauge surface of each steel tooth cone.

“The new premium series roller cone drill bit line advances our popular standard line of roller cone bits into the premium markets, bringing reliability and cost effectiveness to our customers in their more demanding applications,” says Hossam Elbadawy, Tercel CEO. “We are very proud of this industry leading seal design which extends our bearing life beyond anything else available on the market today.”

Tercel’s premium bearing roller cone bit line has precision machined bearing races that are matched to provide the optimum fit and finish for extended operations, even with parameters of higher RPM (revolutions per minute) and heavy WOB (weight on bit). The bearings are designed and machined for reliability and consistency.

Inconel 718 (NiCr 19 FeNbMo DIN), 36-39 HRC, Continuous cut, Flood Coolant. Cutting Conditions: 91 m/Min (300 sfm), 0,15 mm/rpm (0.006 ipr), 0,25 mm doc (0.01” doc)

It features a revolutionary coating applied to an ultra-fine grain carbide substrate for superior layer adhesion and delivers up to 50% greater tool life, more predictable processes and improved productivity when working with difficult to machine superalloys, says the tooling expert.

Metals such as Inconel 718 and Stellite 31 are notorious for causing rapid wear and unpredictable tool life, KCS10B is proven to reduce DOC notching and extend tool life from three minutes to upwards of five minutes in roughing operations. Tool life in finishing operations fares even better, with visible cratering and subsequent tool failure often delayed by a factor of two or three compared to competitive brands.

The launch took place at the Abu Dhabi International Petroleum Exhibition and Conference (ADIPEC) from 10 – 13 November 2014 in Abu Dhabi, UAE.

“Aside from a smoother surface, the new coating process also allows us to create a much sharper edge. Our advanced honing and edge-preparation process reduces the friction that leads to heat, which further improves tool life. It also means less built-up edge, another common failure mode in super alloy materials. When coupled with the excellent dimensional accuracy that Kennametal turning inserts are known for, shops can now expect the increased performance, stability, and predictability needed to be successful with these challenging alloys.”

​Kennametal’s KCS10B is described as “turning grade is the new champion for machining nickel-, cobalt- and iron-based metals for aerospace and beyond”.

The new insert is available in the most popular turning insert shapes, sizes and geometries. Positive and negative rake inserts are available, as well as various chip formers, edge preparations, and geometries, making KCS10B the ideal solution when turning iron-based (S1), cobalt-based (S2), or nickel-based (S3) alloys.

Robert Keilmann, senior global product manager for turning, explains that the secret behind the success of KCS10B is Kennametal´s proprietary High-Power Impulse Magnetron Sputtering (High-PIMS) technology. “Rather than the light rain of droplets that fall on cutting tools during traditional PVD coating processes, High-PIMS generates a fine mist of AlTiN, building a series of »extremely thin, smooth, and wear-resistant layers.