Comparative test
Extensive testing in a variety of machining applications has shown that SAF™ 2507 bars provided better machinability than the nearest competitor material with 23% better tool life and overall savings on all machined components:
- 168 holes drilled before tool failure, compared to 135 for competitor material
- 168 holes tapped, compared to 112
- Tool wear less than 0.3 mm for all operations
- Better chip formation
- Less power consumption
Project scope
To compare the machinability of SAF™ 2507 and material from the closest competitor.
Operations:
Turning, drilling, and tapping with specified machining data.
Parameters:
- Cutting tools and tool wear
- Raw material surface finish
- Power consumption of the machine tool
- Chip formation and chip clearance during machining
Turning
- Rough and medium machining at cutting speeds 60, 80, 100, and 125 m/min
- 100 mm diameter round bar
Test criteria;
- Failure of cutting tool or flank wear of 0.3 mm
Cutting tool failures considered:
- Edge fracture
- Plastic deformation
- Chipping
- Notch wear
- Flank wear
Cutting data
| Insert geometry | CNMG 120412MM |
| Grade | GC2025 |
| Feed | 0.3 mm/rev |
| Coolant | Castrol Alusol SL 51XBB |
| Machine tool | MAZAK INTEGREX MACH 2 |
Results
- SAF™ 2507 performed better in terms of tool life and tool wear
- The grade gave longer tool life in both rough and medium turning operations
- The average tool wear for the grade was always less than the test criteria of 0.3 mm tool wear
- The competitor material had the highest tool wear and lowest tool life at both 60 and 125 m/min
| Vc m/mm | SAF™ 2507 | 1.4410 (competitor) | % savings |
| 60 | 1100 seconds | 886 seconds | 24 |
| 80 | 690 seconds | 663 seconds | 4 |
| 100 | 610 seconds | 610 seconds | - |
| 125 | 478 seconds | 390 seconds | 22 |
Chip formation
Test conducted at:
- Cutting speeds 70 and 90 m/min
- Five different combinations of feed and depth cuts
The grade provided better chip-breaking at both low and high feed rates compared to the competitor material and a short helix form was achieved. Short chips enable a better cutting operation, longer tool life and less chip clearance time on the machining tool.
Drilling
Test criteria:
- of holes targeted: 257
- Cutting speed: 40 m/min
- Feed rate: 0.08 mm/rev.
Drilling tool:
- 8.7 5xD Cod. 860.1-0870-044°1-MM 2214
Test analysis:
- Machinability
- Tool life
- Power consumption
- Chip form
SAF™ 2507 produced 168 holes against 135 holes for the competitor material and consumed 18% power compared to the competitor material which consumed 30% power.
Tapping
Test criteria:
- of holes tapped: 257
- Cutting speed: 4 m/min
Tapping tool:
- 5 6H – Code E404M10
Test analysis:
- Tool failure
SAF™ 2507 tapped 168 holes against 112 for the competing material and could even be used for further tapping. The tapping tool used for the competing material had chipping failure on the tool tip.