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Kyocera: Parting Solution for Small Part Machining

Kyocera Corporation has developed the parting solution "KGZ" specifically for small part machining.

When machining small parts, an indexable insert with a cutting edge width of a few millimeters is used for cuts up to the center of the respective workpiece. This results in high stress on the tool, with the occurrence of chatter marks and the breakage of the holder being significant problems. Additionally, operating the machine requires an experienced operator who can precisely and quickly change the indexable inserts in tight spaces.

The new parting solution "KGZ" features a newly developed clamping device with three special mechanisms to securely fix the indexable insert, suppress chatter marks, and enable stable machining. The clamping surface of the tool holder, which is frequently subjected to stress, is designed to distribute tension evenly. This increases durability and allows for highly efficient machining. Additionally, the new indexable inserts have a V-shaped groove structure on the top to improve grip and machinability.

The "KGZ" parting solution also introduces the "PR20 series," a newly developed grade of PVD-coated indexable inserts. The new "MEGACOAT®1 NANO EX" coating offers high oxidation and wear resistance at high temperatures, resulting in precise and stable machining of steel, stainless steels, and cast iron with a long tool life.

Features of the "KGZ" Parting Solution

1. With three innovative mechanisms, the clamping device enables particularly stable and highly efficient machining.

The newly designed tool holder improves the holding force of the indexable insert and the durability of the tool holder with three special mechanisms: (1) gap, (2) top clamp, and (3) stopper.

• Slot: The indexable insert is pressed directly from above into the holder and securely fixed. Generally, it is structurally challenging to mount the insert directly above for a parting tool. However, the "KGZ" parting solution features a beveled slot with an inclined groove that, when tightening the fastening screw directly above the indexable insert, exerts an effective holding force.

• Top clamp: To increase the holding force, the indexable insert is pulled inward by the clamp. The special design exerts an inward force when clamping the indexable insert, preventing the workpiece from slipping.

• Stopper: The stopper distributes the load over a large area, thus improving the durability of the tool holder. The "KGZ" parting solution uses a blunt part of the holder as a stopper. This creates a large contact area that absorbs the load and impact on the indexable insert and distributes the stress on the tool holder. This reduces the wear of the stopper to about one-third compared to products from other manufacturers. The improved durability of the tool holder enables highly efficient machining under high loads.

2. The specially designed V-shaped groove enhances the holding force and facilitates the mounting of the indexable insert.

The V-shaped groove on the top of the indexable insert is designed with different angles and shapes to improve holding force and significantly simplify assembly.

• Groove at the ends of the indexable insert The ends taper more sharply than the middle part of the groove. This design reduces play during insert assembly and facilitates the correct fit of the insert to the tool holder. This prevents incorrect assembly and eases machining in tight spaces.

• Center of the groove In the middle part of the groove, the angle increases. This enhances the holding force of the indexable insert as the clamping force from above is distributed over a larger area.

3. The newly developed inserts in the "PR20 series" utilize the special nano-coating "Megacoat Nano EX" to enable highly precise, durable, and stable machining of steel, stainless steels, and cast iron.

Along with the "KGZ" parting solution, Kyocera has introduced a new PVD coating specifically designed for grooving and parting applications: the "PR20 series." From the unique coating process emerged a special nanocoating exclusive to the PR20 series: "Megacoat Nano EX for Grooving and Parting." Compared to products from other companies, this coating offers approximately twice the wear resistance in steel machining, as it primarily consists of aluminum (Al), known for its high thermal and wear resistance. The PR20 series ensures high precision, long tool life, and stable machining of steel, stainless steels, and cast iron.