Kennametal KYS40 solid ceramic multiplies cutting speeds in nickel-based alloy

Two types of Kennametal KYS40 solid ceramic end mills are available, a six-fluted version for face milling and profiling; and a four-fluted, necked version for slot milling and pocketing. Both product lines allow ramping, helical interpolation, and trochoidal machining strategies as well. The wear mechanisms and wear indication on the solid ceramic end mills is completely different from carbide, allowing ceramic end mills to be run far beyond the point where carbide tooling would need to be replaced. For this reason why this KYS40 grade end mill is a throw-away type of tooling to allow usage beyond regular type of wear. KYS40 Beyond grade ceramic in both the four-flute and six-flute versions features an enlarged core design that improves tool rigidity and reduces deflection at high cutting speeds. Optimised end geometry and a 40º helix angle increase shearing action and chip evacuation. In tests, roughing the profile of a small turbine blade made of Inconel 718, machined dry, the EADE four-flute end mill was run at 645 m/min fed at 0.03 mm/z. Depth of cut was 0.5 mm and width of cut was 11.4 mm. Compared to a conventional solution, the EADE four-flute mill lasted three times longer doing the roughing in less time. This application resulted in three times more parts being produced per mill. The six-flute EADE solid ceramic end mill was tested profiling a blisk (blade integrated disk) made of Inconel 718 and run with compressed air for chip evacuation. Unlike conventional carbide tooling, roughing to near net shape creates chips closer to dust than traditional curled chips, requiring only compressed air to blow them out of the cut. Test conditions were cutting speed of 679 m/min, feed of 0.03 mm/z and the depth of cut varied up to 0.5 mm. The results were two blisk segments machined with one tool at a 12-minute machining time per segment. Kennametal is offering the KYS40 ceramic end mills in the range of 4-12 mm. Running the tool does not require use of special clamping, the use of common high performance collet, power, or hydraulic chucks is sufficient, although the chuck must be able to run at the high speeds necessary for superalloy machining. To ensure highest tool life, final balancing is recommended. The EADE solid ceramic end mills are featured in a free Kennametal Innovations iPad app from the iTunesTM App Store