Ceramic and CBN for steel mill applicationsTools for mill roll turning｜ Ceramic and CBN inserts

High speed performance, longer tool life, and better part surface finish compared to carbide tools

Ceramic inserts effectively perform at high speed ranges

The best selection of Ceramic and CBN grades to successfully machine the application.
Light to heavy edge preparations to handle any cutting conditions.

Features

Ceramic insert advantage

  • Harder material than carbide for high-speed machining
  • A lack of metal in its composition allows it to minimize tool damage from heat
  • Improved part surface finishes due to stable performance of alumina TiC ceramic.
  • Cost effective alternative to CBN

CBN grades:

  • High CBN content increases impact resistance
  • Increased wear resistance machining abrasive materials
  • B30 & B99 are ideal for carbide rolls

Tooling application

Turning mill roll materials

Features of insert grades

Insert grade selection

Scroll the table →

Roll material Application Grade Cutting speed (m/min) Feed(mm/rev) DOC(mm) DRY WET
High speed steel (HHS) roll Rough to semi-finishing Whisker ceramic WA1/WA5 ~ 40 0.3 - 0.5 * 5-15% of insert diameter (approximate) ● -
Finishing CBN B22/B36
Hardened steel roll Semi-finish to finishing Alumina ceramic HC2/HC7 80 - 200 0.5 - 0.8 ● -
Finishing CBN B22/B36
Cast iron roll
Chilled iron roll 		Semi-finish to finishing Alumina ceramic HC2/HC7 40 - 80 0.3 - 0.5 ● -
Finishing CBN B22/B36
Cast iron roll
Ductile cast iron rolls
CPM rolls (ex. Powdered metal)
Carbide rolls
Rough to semi-finishing Silicon nitride ceramic SX9 40 - 120 0.5 - 0.8 ● -
Finishing CBN B22/B36
Carbide rolls Rough to semi-finishing Whisker ceramic WA1/WA5 ~ 40 0.3 - 0.5 ● -
Finishing CBN B22/B36

Ceramic insert application guideline:
① shape characteristic

Edge strength increases as the insert geometry angle increases.
Note that as the insert strength increases so do cutting forces. 

Ceramic insert application guideline :
② edge preparations

Insert damage can be reduced by increasing the edge preparation.
Insert machining stability will be improved during roughing.

Ceramic insert application guideline :
③ Minimize overhang

By minimizing the toolholder overhang the setup is more rigid and eliminates chatter. (a main cause of insert chipping)

Industry specific tools

NTK provides specialized tools with industry specific insert geometries and coordinated holders.

Case study

Forming roll
Material :
SKD11 (Hs 70-75)
Cutting speed :
100 m/min
Feed :
0.25 mm/rev
DOC :
0.3 mm
Coolant :
DRY
HC7

2 pcs/ corner
Competitor's black ceramic

1 pcs/ corner

HC7 performed with 2 times longer tool life compared to competitor's black ceramic.

Bending roll
Material :
S45C Carbon Steel (1045 steel) (Hs 80-)
Cutting speed :
60 m/min
Feed :
0.5 mm/rev
DOC :
0.3 mm
Coolant :
DRY
WA1

2 pcs(6,000L)/ corner
Competitor's black ceramic

1 pcs(3,000L)/ corner

WA1 achieved twice the tool life compared to competitor's black ceramic.
Customer: "I had always used the same black ceramic product, but now I see the performance difference between products."

Tool lineup

View Catalog Information

Please check product catalog for tooling lineup

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