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KYOCERA Cutting Tool Inserts in New Coated Carbide Grades Improve Cast Iron Machining

New CA3 Series and K Series chipbreakers maximize performance from rough cutting to finishing

September 30, 2016
Kyocera Corporation (President: Goro Yamaguchi) announced today that it has developed a new line of indexable cutting tool inserts to improve cast iron machining. Made from new grades of CVD coated-carbide materials, Kyocera’s CA3 Series and chipbreaker K Series inserts offer significant improvements in machining cast iron components for automobiles, industrial machinery and many other heavy-duty applications. The new inserts address rising demand for metalworking tools that can deliver stable machining performance over a wide range of cutting conditions.

The CA3 Series uses a newly developed CVD coating with a pink-gold finish over a carbide base metal. Kyocera has improved the adhesion strength of the coating layers to ensure longer tool life and consistent processing of cast iron. Further, newly designed blade-edge shapes on the new chipbreakers maximize performance even under high-load machining.

Three types of new materials and chipbreakers are available to address all aspects of cast iron machining, from rough cutting to finishing. Kyocera will continue to develop optimal insert grades to maximize users’ productivity in diverse cutting conditions.
Image: Carbide inserts with new coatings and chipbreaker geometries (clockwise top left: KQ, KG, KH)
Carbide inserts with new coatings and chipbreaker geometries
(clockwise top left: KQ, KG, KH)

Product Overview
Product New Material: CA3 Series New Chipbreaker: K Series
CA310 CA315 CA320 KH KG KQ
Total Lineup (Insert Types) 206 * 206 * 206 * 54 57 36
Recommended application Gray cast iron
(first choice)
Ductile cast iron
(first choice)
Ductile / gray cast iron
(to optimize stable processing)
Heavy interrupted to interrupted cutting
(first choice)
Interrupted to continuous cutting Sharpness focused
Production location Kyocera’s Kagoshima Sendai Plant (Kagoshima Prefecture, Japan)
*The total number of CA3 Series insert types includes products in the new chipbreaker K Series.

New Material: CA3 Series

Kyocera has used newly developed CVD coating technology for cast iron machining in its CA3 Series. In addition to increasing the adhesion strength of the coating layer by optimizing the crystalline structure of each layer, abrasion and fracture resistance have been increased by adopting hard-surface coatings and improved surface layer coating conditions. Kyocera has also adjusted the balance between layers for various applications to enhance tool life and ensure consistent cutting.

Material Application Description
CA310 Gray cast iron
(first choice)
Focuses on abrasion resistance in gray cast iron machining (ductile cast iron also possible) with increased aluminum oxide layer thickness.
CA315 Ductile cast iron
(first choice)
Optimizes performance in ductile cast iron machining (gray cast iron also possible) through adjustments of coating layer thickness.
CA320 Ductile / gray cast iron
(to optimize stable processing)
Improves stability in heavy interrupted cutting of ductile and gray cast iron with reduced overall CVD coating layer thickness.

New Chipbreaker: K Series

The surface of a cutting tool insert incorporates grooves and uneven rough areas called “chipbreakers” that efficiently break and remove chips of metal from the workpiece. A chipbreaker’s purpose is to ensure chip evacuation, thereby preventing quality problems and process interruptions caused by chip buildup and/or damaged blade edges.

Kyocera’s K Series features three newly designed edge shapes to maximize performance when combined with the new materials in the CA3 Series. By creating specialized chipbreaker shapes for specific applications, higher stability and cutting consistency can be expected even under high-load cutting conditions.

Chipbreaker Application Description
KH Heavy interrupted to interrupted cutting
(first choice)
High stability with flat land;
for strong intermittent machining and casting scale removal.
KG Interrupted to continuous cutting Improved fracture resistance with positive land;
for continuous machining and components with long dimensions.
KQ Sharpness focused Achieves both low resistance and edge strength.
For thin-walled materials and high-precision components.

Image: KH Chipbreaker Image: KG Chipbreaker Image: KQ Chipbreaker
KH Chipbreaker KG Chipbreaker KQ Chipbreaker