Mitsubishi Cermet Inserts

Key Features:

• Cermet Composition:
  Mitsubishi Cermet Inserts are made from a composite material consisting of ceramic and metallic compounds. This combination provides the benefits of both materials: the hardness and wear resistance of ceramics and the toughness and fracture resistance of metals. This unique blend allows for extended tool life and stable cutting performance in various challenging machining tasks.

• High Wear Resistance:
  The hard ceramic phase in the Cermet inserts provides superior resistance to wear and abrasion, ensuring that the cutting edges remain sharp for longer periods, even in high-volume and high-speed operations. This makes them ideal for long-lasting cutting tools in continuous turning and milling operations.

• Excellent Surface Finish:
  One of the standout characteristics of Mitsubishi Cermet Inserts is their ability to produce smooth, high-quality surface finishes on the machined workpiece. These inserts are particularly effective in fine finishing applications, where surface quality is a key factor. They help achieve a superior finish with minimal tool marks, reducing the need for secondary operations.

• High Heat Resistance:
  Cermet inserts are designed to handle the heat generated during high-speed cutting without losing their hardness or structural integrity. This makes them suitable for high-temperature machining applications where other materials may struggle, particularly when cutting stainless steel, superalloys, and cast iron.

• Chip Control:
  Mitsubishi Cermet inserts feature a well-engineered chipbreaker design that enhances chip control and minimizes the chances of chip recutting, thus improving the overall cutting efficiency. Efficient chip removal also helps in reducing heat buildup, preventing material buildup on the cutting edge, and prolonging tool life.

• Versatility Across Materials:
  These inserts are engineered for use with a variety of materials, including stainless steel, high-carbon steel, cast iron, heat-resistant alloys, and tool steels. Their excellent combination of toughness and hardness makes them an ideal choice for general-purpose machining as well as high-precision finishing of difficult-to-machine materials.

• Precision Geometries and Coatings:
  Mitsubishi offers a wide range of insert geometries (such as round, square, triangle, and diamond shapes) and coatings tailored to specific applications. The coatings enhance the insert’s resistance to wear, oxidation, and thermal degradation, while providing additional lubrication during cutting. The right combination of geometry and coating can significantly improve the performance in different cutting scenarios.

Applications:

Mitsubishi Cermet Inserts are ideal for a variety of machining applications, including:

• Turning:
  Cermet inserts excel in precision turning applications, particularly when high-quality finishes are required. They are effective for both roughing and finishing operations on a wide range of materials, especially stainless steel, high-carbon steels, and cast iron.

• Milling:
  Cermet inserts are used for milling operations such as face milling, end milling, and slot milling. Their ability to maintain sharp cutting edges for extended periods makes them suitable for high-speed milling operations that require minimal tool wear and excellent surface quality.

• Boring:
  In boring operations, Mitsubishi Cermet Inserts are highly effective in producing precise and smooth bores, especially in materials like stainless steel and cast iron. Their sharp edges and wear resistance ensure consistent performance throughout the machining process.

• Grooving and Parting:
  These inserts are often used in grooving and parting operations, where their high precision and smooth cutting capabilities result in clean and accurate cuts, minimizing burr formation.

• Threading:
  Mitsubishi Cermet inserts are suitable for thread cutting in stainless steels and alloy steels, producing threads with excellent surface finishes and tight tolerances.

• Finishing Operations:
  Their exceptional ability to deliver smooth, high-quality finishes makes them a top choice for finishing applications, particularly in industries that require tight tolerances and fine surface quality, such as aerospace and automotive manufacturing.

Advantages:

1. Superior Tool Life:
   Thanks to the ceramic-metal composition, Mitsubishi Cermet inserts offer significantly longer tool life than traditional carbide inserts, reducing the frequency of tool changes and downtime.

2. High Cutting Speeds:
   The heat resistance and sharp cutting edges of the inserts allow for high cutting speeds without compromising performance, improving productivity and cycle times.

3. Excellent Surface Finish:
   The inserts are specifically designed for finishing operations, where a high-quality surface finish is essential. The smooth cutting action ensures minimal burrs and a fine surface on the finished workpiece.

4. Reduced Tool Wear:
   The advanced wear resistance of Mitsubishi Cermet inserts ensures minimal edge degradation, even under continuous cutting conditions. This leads to reduced tool wear and better consistency over long periods of use.

5. Improved Productivity:
   By allowing for high-speed cutting and maintaining edge sharpness over longer periods, Mitsubishi Cermet Inserts can increase productivity while maintaining precision, making them ideal for high-volume manufacturing.

6. Versatile and Cost-Effective:
   These inserts are suitable for a wide range of materials, making them an excellent choice for companies that need to handle a variety of machining tasks. Their durability and longevity also reduce the cost per part, offering an overall cost-effective solution.

Types of Mitsubishi Cermet Inserts:

• ISO Inserts:
  Available in standard geometries such as square, round, triangular, and octagonal shapes, suitable for turning, milling, and parting operations.

• Coating Options:
  Mitsubishi Cermet inserts come with various coating options, including TiN (Titanium Nitride), TiCN (Titanium Carbonitride), and AlTiN (Aluminum Titanium Nitride), which provide additional protection against wear, heat, and oxidation.

• Chipbreakers:
  Various chipbreaker designs are available to improve chip control, reduce cutting forces, and enhance surface finish, ensuring the most efficient cutting performance for each specific application.

• Grade Options:
  Mitsubishi offers different grades of Cermet inserts for roughing, semi-finishing, and finishing operations, optimized for specific material types and cutting conditions.

Technical Specifications:

• Material: High-performance Cermet (ceramic-metal composite)
• Insert Shapes: Square, round, triangular, diamond, octagonal, rectangular
• Coating Options: TiN, TiCN, AlTiN, CVD, PVD
• Grades: Tailored for different cutting operations (e.g., finishing, roughing, semi-finishing)
• Hardness: Typically HRC 85-90 for high hardness and wear resistance
• Applications: Turning, milling, boring, grooving, threading, cutting cast iron, stainless steel, high-carbon steel, heat-resistant alloys

Conclusion:

Mitsubishi Cermet Inserts represent the pinnacle of cutting tool technology, offering a unique combination of high hardness, wear resistance, and heat resistance. Ideal for precision machining of tough materials like stainless steel, cast iron, and superalloys, these inserts deliver outstanding results in finishing operations, ensuring a superior surface finish and long tool life. Whether used in turning, milling, or boring, Mitsubishi Cermet Inserts provide reliable, high-performance solutions for even the most demanding applications, improving productivity and quality across industries.