SUMITOMO ELECTRIC AC1135U Small Parts Turning Application Guide

1. Semiconductor manufacturing equipment components (316 stainless steel)

The dual melting 316 stainless steel components in semiconductor equipment require extremely high cleanliness and dimensional accuracy. In continuous external turning and end face machining, the DCGT21.50-MESI-AC1135U tool is used with cutting parameters of vc=365 SFM, f=0.0016 IPR, ap=. 002-0.008 ". Compared with traditional competitors, AC1135U effectively suppresses cutting edge chipping and increases tool life by an astonishing 12.5 times. Competitors can only process 20 pieces, while AC1135U has consistently processed 250 pieces, greatly reducing downtime for tool changes.

2. Medical equipment components (304 stainless steel)

Medical device components typically require extremely high surface integrity. When processing 304 stainless steel medical components, DCGT21.50MESI-AC1135U is used for continuous outer circle machining with a cutting parameter of vc=130 SFM. In the case of failure due to surface roughness exceeding the standard after processing 5000 pieces with competing tools, AC1135U successfully processed 10000 pieces, with a tool life twice that of competing D-grade tools, and the processed surface quality remains excellent.

3. Automotive components (pure iron and STKN materials)

In the manufacturing of automotive parts, pure iron materials are prone to causing tool tip breakage and burrs. Use CCGT32.50.5MESI-AC1135U for intermittent precision machining, with cutting parameters of vc=500 SFM and f=. 004 IPR. AC1135U minimizes tool tip chipping and achieves a tool life 1.4 times that of its competitors (700 pieces vs 200-500 pieces). When processing STKN automotive components, AC1135U effectively suppresses the wear of the front cutting surface, achieving a 1.5-fold increase in tool life and ensuring that there are no burrs on the external chamfers.

4. Beverage and electrical equipment components (304 stainless steel)

AC1135U also performs well in the continuous outer circle processing of 304 stainless steel beverage equipment components. Under the working condition of vc=165 SFM, compared with competitors, its tool damage is minimal, and it still maintains good condition after processing 3000 pieces. In the processing of 304 stainless steel electrical equipment components, AC1135U significantly reduces the phenomenon of chipping, and the surface quality of the processed material is much better than that of conventional materials under the same processing quantity.

Long term verification of surface quality and dimensional stability

In addition to the improvement of tool life, the dimensional stability and surface roughness control of AC1135U in long-term machining are also remarkable. In the comparative test of external turning of 316 stainless steel, after a cutting distance of 11 miles, the surface of the workpiece machined by AC1135U remained smooth, while the surface of the workpiece machined by conventional materials showed obvious tearing and pulling.

In the variable speed test of end face machining (vc=65 to 400 SFM), AC1135U can still achieve excellent machining surface quality at low speeds (65 SFM), thanks to its excellent anti adhesion coating. In long-term dimensional tolerance testing, the size fluctuation of AC1135U workpiece is minimal and can maintain high-precision dimensional tolerances for a long time, while the size fluctuation of conventional materials and competitor grade A significantly increases with the increase of cutting distance.

In cutting processing, AC1135U also demonstrated strong advantages. Using GCMN2002-GF cutting tool for cutting 316 stainless steel, AC1135U achieved a tool life 1.7 times that of conventional materials at a high speed of n=3000 min ⁻¹. Even when processing 125 pieces, it effectively reduced cutting tearing and ensured the smoothness of the cut surface.

Complete tool and boring system support

AC1135U is not just a material grade, it has a complete tool product line support. In terms of turning, various specifications of G-grade positive angle inserts are provided, including 80 ° diamond (CC type), 55 ° diamond (DC type), triangle (TC/TP type), square (SC type), etc. These blades offer a wide range of rounded corners (such as 0.2, 0.4, 0.8, etc.) and inscribed circle diameters to meet the contour machining needs of different precision parts.

In the field of slotting and boring, AC1135U material is applied to GWC slotting tool systems and PSZ series quick change tool heads. The TGA R/L series square slotted blades offer a variety of cutting width options from 0.33 inches to 2.80 inches, and have a maximum cutting depth capability of 3.00 inches. For small aperture inner circle machining, the BXBR series boring bars (such as BXBR02005R to BXBR05020R) are perfectly combined with AC1135U material, providing a minimum boring diameter from 2.0mm to 5.0mm, and equipped with corresponding HBX series bushings to ensure rigidity in small aperture machining.