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

Ceramics' effective performance is achieved at high speed ranges

Choose the best grade from a selection of ceramic and CBN grades to successfully machine the application
Light to heavy edge preparations to handle any cutting conditions.

Features

The ceramic 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 its low plasticity

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 point:
① shape characteristic

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

Ceramic insert application point:
② edge preparations

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

Ceramic insert application point :
③ Minimize overhang

By minimizing the toolholder overhang the setup is more rigid and eliminates chatter. (a main can cause 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 :
100m/min
Feed :
0.25mm/rev
DOC :
0.3mm
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 :
60m/min
Feed :
0.5mm/rev
DOC :
0.3mm
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 difference between products."

Tool lineup

View Catalog Information

Please check product catalog for tooling lineup