Simply rotating the insert in the holder so that it faces the opposite direction will allow you to continue using the cutting edge even after it has gotten dull. The MGMN Insert is a type of cut off insert that offers a significantly longer tool life than the majority of other inserts. A chip breaker that has been specially built enables the production of thinner chips, which in turn promotes improved chip flow. The cutting edge of the MGMN Insert is very sharp, resulting in a powerful cutting force and good processing efficiency. The chip breaking range is rather broad with double-end cutting, which is a frequent type of machining groove. There are many different kinds of workpiece materials, and general-purpose grades are used for those materials. Inserts with two edges offer a reduction in the overall cost per edge. MGMN was developed with grooving applications in mind especially. The MGMN system cuts down on cycle time and boosts productivity by allowing users to groove, turn, face, or copy in a single operation and by making use of an MGMN Insert that has been purpose-built for use in grooving operations. The Huana MGMN Insert is suitable for a broad variety of applications, including the continuous and interrupted cutting of stainless steel.
Chipbreaker Styles For MGMN Inserts
The MGMN inserts have chipbreakers G, M, and H that were built expressly for the purpose of producing thinner chips and ensuring improved chip flow. MGMN inserts come equipped with a chip breaker that has been built expressly for the purpose of enabling thinner chips to be formed, which in turn promotes improved chip flow. Coated inserts for machining steel, stainless steel, exotic materials, or cast iron are available in the MGMN series, which features insert widths ranging from 1.5 to 5 millimeters. MGMN inserts have a one-of-a-kind W-shaped clamping mechanism that not only improves the stability of the machining process but also makes it possible to do several operations with a single toolholder.
MGMN Insert Models
Feel the grooving innovation that can only be provided by MGMN200, MGMN300, and MGMN400. Changing the regular insert for the grooving ones is as easy as loading in the Huana MGMN inserts, adjusting the diameter, and you’re good to go. Grooving and separating applications that need a higher degree of accuracy can also make use of MGMN inserts.
How Should One Go About Selecting the Cut Off Insert for the Grooving Application?
The choice of tool for grooving operations is context dependent, as is the case with the majority of turning applications. Tool selection is not complicated when dealing with radial grooving procedures. In order to successfully finish the groove and safely clamp the insert, the toolholder in question must have the appropriate depth of cut capabilities. Because the stiffness of the tool has an effect on the amount of time the insert is able to do its function, it is in your best interest to select the toolholder that has the smallest cutting depth among those that will do the job. Inserts tend to have a lifespan proportional to the level of stiffness and clamping force they possess. The choice of insert is determined by the material of the workpiece as well as the cycle time requirements. The chip can be readily managed and will not get stuck inside the groove if the operation has the correct geometry. Either the shorter inserts with a single edge or the longer inserts with two edges may be used to perform radial grooving operations extremely well. Both of these options are available.
The rigidity of the toolholder is even more crucial for groove-turning operations. This is due to the fact that the forces exerted during groove turning are perpendicular to the strength of the tool. To reiterate, it is advisable to choose a tool holder that has a cutting depth that is as little as possible while still being able to complete the task. The longer two-edge form is the insert of choice for groove turning because longer inserts are better equipped to resist the side forces created in the turning process. This makes longer inserts the preferred choice for groove turning. The shape of the groove turning insert is also extremely important; it is necessary for the insert to have very good chip control qualities in both the radial and axial cutting directions. Inserts for groove turning are designed with the appropriate chip breaker form around all of the cutting edges; however, the form of this chip breaker may vary significantly from the front of the insert to the sides in order to accommodate the different chip flow that occurs during axial and radial grooving.
Choose the largest insert that you can get away with using for the work as a guideline, as this applies to all grooving procedures in general. This gives the insert with the greatest strength to manage the widely changing forces that occur throughout the various phases of the cut, and the insert also has greater mass to withstand the heat that is created, particularly at the bottom of the groove.
- How may work-hardening be avoided in grooving operations?
During the process of cutting metal, the material of the workpiece is deformed below the cutting edge of the insert, which results in the production of work hardening. If you want the cutting edge to generate as little pressure as possible, you should choose an insert that has a moderately sharp edge preparation. Make sure that the feed rate is significantly higher than the bare minimum that is required for the insert shape and breadth.
- What happens if the speeds/feeds are incorrect?
There is a vast range of impacts that might occur, and each one is determined by how much the cutting parameters deviate from the specified levels. There is a possibility that the life of the instrument will be shortened. Incorrect settings can also result in chipping of the cutting edge, significant chip control problems, poor surface smoothness, and other concerns; at its worst, this can cause insert fracture as well as damage to both the workpiece and the toolholder.
- What role does an insert’s geometry, particularly at the cutting edge, have in grooving?
The shearing action that occurs during the process of cutting metal is determined, in part, by the geometry of the cutting edge, which also influences the cutting edge’s overall strength. A cutting edge that is both sharp and positive will shear the material of the workpiece with a low cutting pressure. As a consequence of this, less heat will be generated, and the material of the workpiece will also have less of a propensity to become work-hardened. The downside to this is that the sharp edge is more likely to chip if there are any breaks in the cut or if the feed rate is increased. A cutting-edge geometry that is more negative and robust will be able to better endure higher forces and interruptions; however, this comes at the cost of higher cutting pressures, more heat generation, and an increased risk of work hardening.
MGMN Insert For Chip Control
The insert has machined surfaces on both sides of the feed direction due to the parting and grooving operations that are performed on it. Therefore, in order to prevent the surfaces from being damaged, the chips need to be made in such a way that they are smaller than the groove. In addition, the chips have to be shaped in such a way that they may be removed from the groove without interfering with the machining process by using lengthy chip coils that are difficult to manipulate. As a result, the chips are created in two different directions: first, they are bent across their width, and then they are rolled together lengthwise to form the shape of a spiral spring. There are three chip control inserts shown in the figure on the left.
In order to create this optimum chip shape, the insert is often equipped with a chip former. This chip former takes into consideration both the circumstances of the machining and the substance of the workpiece. During the milling process, the structure is fashioned in such a way that it forms a bank that the chips may climb against. After a certain number of rotations, the chips are programmed to break on their own. The width of the insert, the height of the bank, the feed rate, and the material that makes up the workpiece all have an impact on the diameter of the spiral spring chips.
- Why would you pick a PVD coating for an MGMN insert?
The coating gives the MGMN insert resistance to heat and wear, and it also acts as a barrier between the carbide and highly reactive chips, which may quickly wear away exposed carbide if it is not there. By directing the heat away from the center of the insert, it is possible to prevent the deformation of the cutting edge, which would otherwise lead to larger forces and, eventually, the failure of the insert. For a variety of different reasons, PVD coatings are utilized for the majority of the grooving and parting processes. When compared to a normal CVD coated tool, a tool with a PVD coating can have cutting edges that are sharper because PVD coatings are thinner and cling to sharper cutting edges better. The cutting edge generates lower forces, which then in turn make less heat, and therefore less wear; and along with a very smooth surface, PVD coatings are less susceptible to built-up edge, which is common in stainless steels and high temperature alloys. The advantage of this is that the cutting edge generates lower forces, which in turn creates less heat, and therefore less wear. The sharper edge also greatly lowers the tool pressure, which helps to prevent work hardening in alloys that are vulnerable to the phenomenon.
Another important consideration is the increased abrasion resistance provided by PVD coatings on tools. In separating procedures, which involve cutting to the center of a solid bar, this becomes an extremely essential consideration. In order to maintain the same cutting speed as the insert cuts its way to the center of the workpiece, the spindle’s revolutions per minute (rpm) must be increased. After reaching the maximum number of revolutions per minute that the machine is capable of, the cutting speed begins to rapidly slow down, finally coming to a stop in the middle. Because of the slower speeds, more stresses are generated on the cutting edge, which makes it more prone to chipping. The dependability of the edge is greatly increased when employing inserts with a harder PVD coating.
When it comes to coating systems in general, there is an inherent tension between the higher wear resistance offered by CVD coatings that contain aluminum oxide and the lower wear resistance offered by PVD coatings that do not. Sharp edges and smooth coatings, in addition to the improved heat and wear resistance of aluminum oxide, are supplied as a result of the utilization of the Huana MGMN technology. Huana MGMN insert provides a larger application range, which simplifies application for the client while still offering outstanding performance as a result of giving all of these advantages combined.
- It is preferable to clear the work area of chipbreaker
Without a chip breaker, there are very few viable options for controlling the chips, and turn-grooving would be an incredibly challenging endeavor. To put an end to the cutting operation and remove the chip, the sole choice available is to run a “peck cycle.” However, this results in a decrease in output, and the chips are still fairly lengthy, which creates further complications. The chip breakers that have been produced for grooving over the course of the previous 20 years have been an incredible advance to the grooving process.
The application must be taken into consideration while choosing the appropriate insert. When doing any type of grooving operation, it is best practice to use the widest insert that can be accommodated by the Huana MGMN insert. MGMN Insert are resistant to heat and wear, and they create a barrier between unprotected carbide and highly reactive chips, which prevents the carbide from being quickly worn away.