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Alumina - e Catalogue PDF
Alumina - e Catalogue PDF
Holding Systems
Introduction to Holding Systems 33
Cl assi fi cati o n of Tool H ol d e r s & Bor i n g Ba r s 33
Tur n i n g To o l Ho l d e r s 35
Indexabl e Dri ll s 40
Mi l l i n g Cutters 41
Troubleshooting
Types o f To o l Fa i l ur e & Sol ut i on s
Milling 43
Endmills 45
Drilling 46
Tur ning 47
Introduction
About Us
As a leading manufacturer, importer and exporter of cutting tools for over 40 years, Safe Tools
Mfg. (Import & Export) Co., provides a one-stop solution for all your engineering needs. Our
mission is helping our clients boost productivity and improve per for mance by offering a vast
portfolio of Tungsten, Carbide and Cer met cutting tools supported by our extensive technical
and experiential knowledge.
Our commitment is to drive value for our clients across the industrial and infrastructure
markets globally. We are driven by our core principles of fair ness, honesty and integrity and
have created lasting relationships with our clients. We are passionate about impacting
change and helping drive innovation via our engineering solutions.
1
Grades & Categorisation
Grade Chart
CVD Characterisation & Application
PVD Characterisation & Application
Uncoated Grades Characterisation & Application
PCD Characterisation & Application
PCBN Characterisation & Application
Chipbreaker Comparison Chart
Grade Comparison Chart - Milling
Grade Comparison Chart - Tur ning Gra des
Grades & Categorisation
Grade Chart
Alumina ® cutting tool grades are classified according to application and type of materials.
There are uncoated carbide grades under the ISO classification of P.M.K., coated grades for
high efficiency cutting, Cer mets for finishing to medium cutting and CBN & PCD for high
speed cutting.
TURNING GRADES
MILLING GRADES
P K AC 3000
THREADING GROOVING
P M K P M K
APX 30 AG 9030 AG 9030 AP 4225 AG 9030 AG 9030
3
CVD Grades Categorisation & Application
AK 6210 K05 - K15 • For high speed turning of grey & ductile Turning
cast iron
• T h r ough sp e c ia l c o a t in g we a r
r e si st a n c e h a s b e e n a c q u ir e d
• TiCN + AL 2 O 3 + MT – Ti(CN)
AP 4535 P25 - P40 • Multi layer coating for general & heavy Milling
machining of steel
• Extremely tough grade, resistant to
changes in temperature
• TiN – TiCN – TiN
4
PVD Grades Categorisation & Application
5
PCD Grades Categorisation & Application
FP PF FP LU SH HQ ZF HF NF FG
NF QF FN SU SA CQ ZM GF SF
AG MF LF SX XP TS HMP
NS
27
NM
N KG E R S
VF K GX ES ST S VF FS
AH NGP GP-K UP FJ XP CB HA 12 ML
MS MJ 17 PP
P IB LRL EI A
SH MM P EX MS HU HS TF MP
SG QM SU GS VL
MP PM MP GU MH PS TM HM GN MT
TM KF UX MA HS GM
HM UG
C H IM
RP MR RP MU GH XS TH HR TNM RT
GR PR UM MX GJ ZS GR NR
KR RM HAS GC
MG HDS GT
HT
WX WF FW LUW SW WP AFW WS
AL AL HP AG AH AL AK AF FL
AS
6
Grade Comparison Chart - Milling
COATED ALUMINA SANDV IK KENNAMETAL S UMI T O MO MI T S UBI S HI K YO C ER A TUNGALOY KORLOY ISCAR TAEGUTEC
P20 AP 4525 GC 1025 TN 7525 ACZ 310 FH 7020 PR 630 T 9115 NCM 325 IC 520M
AP 4535 KC 525M ACZ 330 VP 15TF PR 830 T 9125 IC 910
STEEL
P30 AP 4525 GC 4230 TN 7535 ACZ 300 FH 7030 PR 630 T 9025 NCM 335 IC 908 TT 7030
AP 4535 GC 1030 TN 450 ACZ 350 VP 15TF PR 730 T 9035 NC 5330 IC 300 TT 7070
MILLING
P40 AP 4535 GC 4240 TN 450 ACP 300 PR 1225 T 9035 PC 3545 TT 8020
PR1230
M20 AM 4530 GC 2025 TN 7525 EH 20Z US 7020 PR 1025 AH 630 PC 9530 IC 908 TT 8020
STAINLESS
M30 AM 4530 GC 2030 KC 735M EH 20Z F 620 PR 1125 AH 645 PC 9530 IC 928 TT 9030
AP 15X VP 15TF IC 328
CAST IRON
K10 AK 5515 GC 1020 TN 5505 ACK 200 F 5010 PR 905 T 5105 PC 215K IC 928 TT 6290
AP 10X TN 5515 VP 15TF T 5115
AP 15X
K20 AK 6220 GC 1020 TN 5520 ACK 300 F 5020 PR 1210 T 5115 PC 6510 IC 5100 TT 6290
AK 6230 GC 3220 VP 15TF T 5125 TT 6030
COATED ALUMINA SANDV IK KENNAMETAL S UMI T O MO MI T S UBI S HI K YO C ER A TUNGALOY KORLOY ISCAR TAEGUTEC
P10 AP 4410 GC 4005 KC 9110 AC 810P UE 6005 CA 5505 T 9005 NC 3010 IC 9150 TT 8115
AC 3000 GC 4015 KC P05 UE 6010 CA 5515 T 9115 CC 115 IC 8150 CT 3000
GC 1525 KC P10 UE 6110 TN 60 GT 730
KT 315 NX 2525
GRADES
P20 AP 4415 GC 4215 KC 9125 AC 820P UE 6020 CR 7015 T 9115 NC 3020 IC 9250 TT 8125
AP 4425 GC 4225 KC 9225 UE 6025 CA 5525 T 9125 NC 3120 IC 8250
STEEL
KC P20
P30 AP 4425 GC 4225 KC 8050 AC 830P UE 6035 CA 6525 T 9025 NC 3030 IC 8350 TT7100
KC P30 CR 7025 T 9035 NC 5330 IC 9350 TT 8135
M20 AM 9020 GC 2025 KC 9240 AC 610M US 7020 PR 1115 AH 630 PC 9030 IC 907 TT 5080
STAINLESS
KC M25
M30 AM 9030 GC 2135 KC 8050 AC 630M US 735 CA 6525 AH 645 PC 9030 IC 907 TT 9080
KC 9245 PR 1125 IC 9300
KC M35
CAST IRON
K10 AK 6210 GC 3205 KC 9315 AC 410K UC 5105 CA 4010 T 5105 NC 6205 IC 4028 TT 7005
GC 3210 KC 9320 UC 5015 CA 4115 T 5115
KC K15
K20 AK 6220 GC 3220 KC 9320 AC 420K UC 5115 CA 4120 T 5115 NC 6210 IC 5010 TT 7015
AK 6230 KC 9325 T 5125
KC K20
7
Tungsten Carbide Inserts
Aluminum Inserts
ISO Tur ning Inserts
Milling Inserts
Introduction to PCD
PCD Inserts
Introduction to PCBN Inserts
PCBN Inserts
Introduction to Cer met Inserts
Cer met Inserts
Tungsten Carbide Inserts
Aluminum Inserts
CUTTING
DES I GNATI ON DIMENSIONS(mm) PRICE
CONDITION
L d S d1 r fn ap INR
CUTTING
DES I GNATI ON DIMENSIONS(mm) PRICE
CONDITION
L d S d1 r fn ap INR
CUTTING
DES I GNATI ON DIMENSIONS(mm) PRICE
CONDITION
L d S d1 r fn ap INR
9
Aluminum Inserts
CUTTING
DES I GNATI ON DIMENSIONS(mm) PRICE
CONDITION
L d S d1 r fn ap INR
CUTTING
DES I GNATI ON DIMENSIONS(mm) PRICE
CONDITION
L d S d1 r fn ap INR
L d S d1 r INR
d
80º 120408-AL 12.0 12.7 4.76 5.16 0.8 300
d1
r S
L d S d1 r INR
r S
10
Aluminum Inserts
L d S d1 r INR
d1
d S
L d S d1 r INR
r
080408-AL 8.3 12.7 4.76 5.16 0.8 325
L S
L d S d1 r INR
80º L t
7º
09T302 9.4 9.52 3.97 4.4 0.2 310
09T304 9.2 9.52 3.97 4.4 0.4 310
09T308 8.8 9.52 3.97 4.4 0.8 310
120402 12.6 12.7 4.76 5.5 0.2 405
120404 12.4 12.7 4.76 5.5 0.4 405
120408 12.0 12.7 4.76 5.5 0.8 405
L d S d1 r INR
11
ISO Turning Inserts
L d S d1 r INR
L d S d1 r INR
d
80º 120408 432 12 12.7 4.76 5.16 0.8 332
d1
120412 433 11.6 12.7 4.76 5.16 1.2 332
r
190608 642 18.5 12.7 6.35 7.94 0.8 691
S
r S
150408 432 14.7 12.7 4.76 5.16 0.8 396
150604 441 15.5 12.7 6.35 5.16 0.4 482
150608 442 15.5 12.7 6.35 5.16 0.8 482
150612 443 15.5 12.7 6.35 5.16 1.2 482
12
ISO Turning Inserts
60º
160404 331 15.5 9.525 4.76 3.81 0.4 291
r
L
160408 332 14.6 9.525 4.76 3.81 0.8 423
160412 333 13.6 9.525 4.76 3.81 1.2 423
d
C
S
r
080404 431 8.4 12.7 4.76 5.16 0.4 355
L S
13
ISO Turning Inserts
DIMENSIONS(mm) PRICE
TYPE
L≈ d S rε INR
60º
TPMR 110304 10 6.35 3.18 0.4 317
d TPMR 110308 9 6.35 3.18 0.8 317
L
DIMENSIONS(mm) PRICE
TYPE
L C s d R INR
C
S
Milling Inserts
XPHT Rectangular
DIMENSIONS(mm) PRICE
TYPE
L d S d1 r INR
SPKN Square
DIMENSIONS(mm) PRICE
TYPE
d=L S b’s m rε INR
11º
L m S
14
Milling Inserts
TPKN Triangular
DIMENSIONS(mm) PRICE
TYPE
L≈ d S b’s m INR
L
d TPKN 2204 22.0 12.70 4.76 1.4 3.55 275
b’s
11º S
m
WCMT Trigon
DIMENSIONS(mm) PRICE
TYPE
L≈ d S d1 r INR
SDMT Square
DIMENSIONS(mm) PRICE
TYPE
L d S d1 rε INR
r
L S
15
Introduction to PCD Inserts
PCD refers to diamond particles which have been sintered together with a binder phase
under high-pressure, high-temperature conditions similar to those used in single crystal
di am o n d sy n t he s is . T he s e s int e r e d P C D ma t eria ls ha v e a v a riet y o f u ses, mo st no t a b ly, for
cutting tools machining non-ferrous metals and non-metallic materials and for wear parts.
An advantage of these materials is that their structure and composition can be engineered
to have properties tailored to specific applications and operations.
As a cutting tool material, PCD is generally recommended for the machining of non-ferrous
work-piece materials where high abrasion resistance is required. Examples of typical work
pi e c e m ate r ia ls a r e a s f ollows : m e t a l ma t rix c o mp o sit e, silic o n a lu minu m a llo ys, c o p per,
ceramics, fiber glass, carbon fiber reinforced plastics, rubber, pre-sintered and sintered
tu n gste n c ar b id e .
MATERIAL TO BE
APPLICATION
PROCESSED
• ALUMINUM A u t o m o b i l e , a u t o m o b i l e s p a r e p a r t s : e n g in e , a ll
kin ds o f s h e ll, be a r in g a n d bic y c le p a r t s .
• ALUMINUM ALLOY
Pr e c i s i o n m e c h a n i a l p a r t s : h y dr a u lic ma c h in e r y
a n d ma c h in e p a r t s .
Ge n e r a l m e c h a n i a l p a r t s : a ll kin ds o f be a r in g s
a n d s c e ws .
SMALLER GRAIN, SUPERIOR SURFACE FINISH LARGER GRAIN, MODERATE SURFACE FINISH
ALUMINA OTHER PCD’s
Micro grain
Conventional PCD’s Grain
16
PCD Inserts
DIMENSIONS(mm) PRICE
TYPE
L C s d R INR
C S
DIMENSIONS(mm) PRICE
TYPE
L C s d R INR
L
VNMA 160408 16.6 9.525 4.76 3.81 0.8 1350
VNMA 160412 16.6 9.525 4.76 3.81 1.2 1350
d
C S
DIMENSIONS(mm) PRICE
TYPE
L C s d R INR
DIMENSIONS(mm) PRICE
TYPE
L C s d R INR
60º L
10º
17
PCD Inserts
DIMENSIONS(mm) PRICE
TYPE
L C s d R INR
DIMENSIONS(mm) PRICE
TYPE
L C s d R INR
DIMENSIONS(mm) PRICE
TYPE
L C s d R INR
d
WNMA 080412 8.7 12.7 4.76 5.16 1.2 1350
R
L S
DIMENSIONS(mm) PRICE
TYPE
L C s d R INR
18
Introduction to PCBN Inserts
PCBN is made by high-pressure, high-temperature sintering of cubic boron nitride with a
binder phase. There are two main groups of binders, metal binders and ceramic binders.
PCBN and diamond are very similar in crystal structure, chemical bond and lattice
parameters and per for m quite similarly in ter ms of hardness and strength. In cutting appli-
cations, the wear resistance of PCBN exceeds 50 times that of tungsten carbide.
MATERIAL TO BE
APPLICATION
PROCESSED
• HIGH-SPEED STEEL
• CO-BASED SUPERALLOYS
• CAST IRON
STRENGTHENING OF CO-BASED
ALLOYS
• SURFACE HARDENING OF M e c h a n ic a l pa r t s
CONSTRUCTED STEEL
• CR-MO ALLOY
• Ni-MO ALLOY
19
PCBN Inserts
DIMENSIONS(mm) PRICE
TYPE
L C s d R INR
DIMENSIONS(mm) PRICE
TYPE
L C s d R INR
DIMENSIONS(mm) PRICE
TYPE
L C s d R INR
RNGN Circular
DIMENSIONS(mm) PRICE
TYPE
Inscribing circle c Thickness s INR
20
PCBN Inserts
DIMENSIONS(mm) PRICE
TYPE
L C s d R INR
DIMENSIONS(mm) PRICE
TYPE
L C s d R INR
DIMENSIONS(mm) PRICE
TYPE
L C s d R INR
R 7º
90º L
DIMENSIONS(mm) PRICE
TYPE
L C s d R INR
21
Introduction to Cermet
Features:
• High thermal conductivity makes it resistant to the heat generated during cutting
Cermet Inserts
DIMENSIONS(mm) PRICE
TYPE
L d S d1 r INR
DIMENSIONS(mm) PRICE
TYPE
L d S d1 r INR
DIMENSIONS(mm) PRICE
TYPE
L d S d1 r INR
d
80º 120408 12.9 12.7 4.76 5.16 0.8 285
d1
r S
22
Cermet Inserts
60º
160404 431 16.5 9.525 4.76 3.81 0.4 285
160408 432 16.5 9.525 4.76 3.81 0.8 285
L
d1
d S
DIMENSIONS(mm) PRICE
TYPE
L C s d R INR
L
VNMG 160408 14.6 9.525 4.76 3.81 0.8 350
C
S
DIMENSIONS(mm) PRICE
TYPE
L C s d R INR
C
S
DIMENSIONS(mm) PRICE
TYPE
L C s d R INR
23
Taps, Drills & Endmills
Introduction to Alumina Tap, Endmill & Drill Grades
Carbide Straight Flute Taps
Carbide Spiral Flute Taps
Carbide Drills T iAlN Coated General Purpose
Carbide Coated General Purpose Flat Endmills
2/4 Flute Flat Endmill - Standard Length
2/4 Flute Flat Endmill - Long Series
2/4 Flute Flat Endmill - Extra Long Series
Carbide Coated General Purpose Ball Endmills
2/4 Flute Ball Endmill - Standard Length
2/4 Flute Ball Endmill - Long Series
2/4 Flute Ball Endmill - Extra Long Series
Carbide Coated High Per for mance Flat Endmills
2/4 Flute Flat Endmill - Standard Length
2/4 Flute Flat Endmill - Long Series
2/4 Flute Flat Endmill - Extra Long Series
Carbide Coated High Per for mance Ball Endmills
2/4 Flute Ball Endmill - Standard Length
2/4 Flute Ball Endmill - Long Series
2/4 Flute Ball Endmill - Extra Long Series
Taps, Drills & Endmills
Introduction to Alumina® Taps , Endmills & Drills
A l u m i n a ® C a r b id e T a p s , End m ills a nd Drills, ma de o n ma c hines lik e t he ANCA a nd W ALT E R,
are e n gi n e e r e d t o inc r e a s e p r od u c t ivit y a nd effic ienc y. Ap a rt fro m t he st rengt h a nd
du rabi l i ty o f A lum ina ® p r od uc t s , a n added b enefit is t ha t siz es c a n b e c u st o miz ed t o s ui t
y o u r n e e ds. We inv it e you t o d is c ov er t he o ne-st o p so lu t io n fo r a ll yo u r engineering ne ed s .
Alumina® Silver
Made fro m Pre m i um Mi c r og r a i n C a r b i d e , t h e s e 2 & 4 F lu t e E n dmills a r e e x c e lle n t f o r g e n e r a l p u r p ose
mi l l i ng i n cl udin g k e yw a y c ut t i n g a n d sl ot tin g . T h e 2 f lu t e e n dmill de s ig n a llo ws f o r g r e a t e r c h ip
cl earance as op p ose d t o 4 f l ut e or h i g h e r e n dmills . U n c o a t e d f o r c o s t e f f e c t iv e pe r f o r ma n c e , t hese 2 &
4 Fl ute Endmi l l s a r e a v a i l a b l e f r om 1 m m t o 2 5 mm. S ilv e r t o o ls a r e b e s t u s e d o n a lu min u m a n d c a s t iron.
25
Carbide Straight Flute Taps
DIMENSIONS(mm) PRICE
TYPE
Thread size Overall length Length of cut Shank Sq width Sq Length Flutes No INR
DIMENSIONS(mm) PRICE
TYPE
Thread size Overall length Length of cut Shank Sq width Sq Length Flutes No INR
26
Carbide Drills TiAlN Coated General Purpose
27
Carbide Coated General Purpose Flat Endmills
2/4 Flute Flat Endmill - Extra Long Series Coated General Purpose
28
Carbide Coated General Purpose Ball Endmills
20
1 2.5 50 360 8 60 1110
25
1.5 4 50 360 10 75 1700
30
2 5 50 375 12 75 2130
40
2.5 7 50 375 14 100 4150
40
3 8 50 390 16 100 4150
50
3.5 9 50 390 16 100 4715
50
4 10 50 450 18 100 5880
50
5 13 50 655 20 100 8005
50
6 18 50 655 25 100 14150
2/4 Flute Ball Endmill - Extra Long Series Coated General Purpose
29
Carbide Coated High Performance Flat Endmills
20
1 2.5 50 552.5 8 60 1683
25
1.5 4 50 552.5 10 75 2686
30
2 5 50 586.5 12 75 3570
40
2.5 7 50 586.5 14 100 6715
40
3 8 50 637.5 16 100 7650
50
3.5 9 50 637.5 16 100 7650
50
4 10 50 731 18 100 9350
50
5 13 50 1054 20 100 13209
50
6 18 50 1190 25 100 20697.5
30
Carbide Coated High Performance Ball Endmills
20
1 2.5 50 612 8 60 1887
25
1.5 4 50 612 10 75 2890
30
2 5 50 637.5 12 75 3621
40
2.5 7 50 637.5 14 100 7055
40
3 8 50 663 16 100 7055
50
3.5 9 50 663 16 100 8015.5
50
4 10 50 765 18 100 9996
50
5 13 50 1113.5 20 100 13608.5
50
6 18 50 1113.5 25 100 24055
31
Holding Systems
Introduction to Holding Systems
Tur ning Tool Holders
Indexable Drills
Milling Cutters
Holding Systems
Introduction to Holding Systems
A l u mi n a ® HOL D I N G S Y S T EM S c a n b e d iv ided int o 3 su b c a t ego ries.
SVVC SVVC
TTIR TTER
33
Classification of Tool Holders & Boring Bars
SWUB SWUB
34
Turning Tool Holders & Boring Bars
35
Turning Tool Holders & Boring Bars
36
Turning Tool Holders & Boring Bars
37
Turning Tool Holders & Boring Bars
38
Turning Tool Holders & Boring Bars
INR INR
39
Indexable Drills
DIMENSIONS(mm) PRICE
TYPE
D L L1 L2 L3 d1 d2 SCREW WRENCH INR
40
Milling Cutters
PRICE PRICE
INSERT SIZE INSERT SIZE
INR INR
PRICE PRICE
INSERT SIZE INSERT SIZE
INR INR
41
Troubleshooting
Types of Tool Failure & Solutions
Milling
Endmills
Drilling
Tur ning
Troubleshooting
Types of Tool Failure & Solutions
SOLUTION
INSERT
CUTTING CONDITION TOOL SHAPE
GRADE
Approach angle
Cutting speed
cutting edge
TROUBLE CAUSES
Chattering at
Depth of cut
Relief angle
Nose radius
Rake angle
Toughness
Hardness
Coolant
Feed
Flank wear Improper cutting conditions
Chattering
Excessive feed
Improper cutting
edge shape
Improper cutting
edge shape
Unstable workpiece
clamping
Lack of number of
cutting teeth
Chattering
Built-up edge
43
Types of Tool Failure & Solutions
SOLUTION
INSERT
CUTTING CONDITION TOOL SHAPE
GRADE
Approach angle
Cutting speed
cutting edge
TROUBLE CAUSES
Chattering at
Depth of cut
Relief angle
Nose radius
Rake angle
Toughness
Hardness
Coolant
Feed
Facture Improper insert grade
Chattering
Excessive overhang
44
Types of Tool Failure & Solutions
ENDMILLS Tool Failures & Solutions : Increase : Decrease : Use : Correct use
SOLUTION
CUTTING CONDITION TOOL SHAPE GRADE MISCELLANEOUS
Machine vibration
Workpiece fixing
Machine rigidity
Number of flute
Length of flute
Cutting speed
TROUBLE CAUSES
Depth of cut
Chip pocket
Relief angle
Lead angle
Toughness
Overhang
Hardness
Coolant
Honing
Feed
Excessive periphery
Improper cutting condition
cutting edge
Improper grade
Excessive overhang
Chattering
Poor straightness
45
Types of Tool Failure & Solutions
DRILLING Tool Failures & Solutions : Increase : Decrease : Use : Correct use
SOLUTION
CUTTING CONDITION TOOL SHAPE GRADE ETC
Clamping workpiece
Machine vibration
Machine rigidity
Flute width rate
Thinning angle
Cutting speed
TROUBLE CAUSES
Relief angle
Guide bush
Point angle
Initial feed
Toughness
Step feed
Hardness
Coolant
Thinning
Honing
Feed
Too sharp cutting edge
Chipping (big relief angle or thinning
edge is too sharp)
Built-up edge
Over lap
Chip burning
Chip clogging
46
Types of Tool Failure & Solutions
TURNING Tool Failures & Solutions : Increase : Decrease : Use : Correct use
SOLUTION
CUTTING SELECTING MACHINE
INSERT TOOL SHAPE
CONDITION CLAMPING
GRADE
TROUBLE CAUSES
Clamping workpiece
Select harder grade
Machine vibration
Holder overhang
resistant grade
Cutting speed
Depth of cut
Nose radius
Rake angle
Coolant
Honing
Feed
Poor precision Insert precision is variable
Unstable machining size
Wet
Vibration, chattering cutting
47
OUR DOMESTIC NETWORK
A HME D A B AD JAMNAGAR
AURANGABAD KOCHI
BANGALORE KOLHAPUR
B HO PA L KOLKATTA
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C O I MB AT O R E MUMBAI
DELHI PUNE
FA R I D AB A D RAJKOT
GOA S UR AT
GURGAON VADODAR A
CORPORATE OFFICE
SAF E T O O L S MFG. (I M POR T & EXPOR T) CO.
6 4 / 3 , 2 N D F L O OR , I NDI A HOUS E, N. R . R OAD,
BANGALORE 560002
ENQUIRIES
alu m in a@ s af e t o ols. c o. in / info@ safet ools. c o. in
+91 80 41695207 / +91 80 41695202
THE FUTURE OF CUTTING TOOLS