SAF™ 2507

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.