Overview

This document is a detailed technical guide and catalog for turning inserts used in machining operations. It covers insert shapes, chip breakers, material grades, coatings, cutting conditions, and availability, providing comprehensive data to optimize tool selection and machining performance.

1. Insert Shapes and Types

Turning inserts are categorized by shape and application, including diamond (80°, 55°, 35°), square (90°), triangle (60°), hexagonal (80°), and round (360°) inserts. Separate tables specify shapes optimized for different materials such as steels, stainless steels, and cast irons. Insert geometry, including corner angles and nose radius, directly influences cutting performance.

2. Chip Breakers

Chip breakers are classified by cutting application: finishing, semi-finishing, medium cutting, and roughing. They differ in cross-sectional shape and chip removal region, with specific types recommended based on material (steel, stainless steel, cast iron) and cutting conditions (depth of cut, feed rate). Proper breaker selection enhances chip control, machining stability, and surface finish.

3. Material Grades for Inserts

HITACHI carbide grades are detailed, categorized by machining type (finishing, general, roughing) and workpiece material (carbon steels, alloy steels, stainless steels, cast irons, hardened materials, non-ferrous metals, super alloys, titanium). Each grade balances mechanical and physical properties such as hardness and toughness to optimize performance.

4. Coating Materials and Features

Coatings include PVD (e.g., IP050S, IP100S) and CVD types (e.g., HG3305), with thicknesses ranging from 5μ to 15μ. Key coating materials are TiN, Al2O3, TiC, TiCN, and Zr-added films. Coatings improve wear resistance, toughness, and chipping resistance, tailored to specific applications like stainless steel, cast iron, and interrupted cutting.

5. Recommended Cutting Conditions

Tables provide standard cutting parameters—depth of cut, feed rate, and cutting speed—matched to insert grades, chip breakers, and workpiece materials. For example, finishing operations with CZ25 inserts recommend speeds of 150–300 m/min and feed rates of 0.1–0.2 mm/rev. These parameters are critical for maximizing tool life and machining quality.

6. Insert Designations and Geometry

The document explains insert designation codes covering shape symbols, clearance angles, chip breaker presence, hole types, thickness, and tolerances (nose height, inscribed circle diameter). Cutting edge conditions (sharp, chamfered, rounded) and feed direction symbols are also described, aiding precise insert identification and application.

7. Cross-Reference of Insert Grades

Cross-references among manufacturers (Hitachi Tool, Tungaloy, Mitsubishi Material, Sumitomo Electric, Sandvik, Kyocera) are provided, highlighting equivalent grades with enhanced wear and breakage resistance. This facilitates sourcing flexibility and informed selection across brands.

8. Catalog Specifications and Availability

The catalog lists insert item codes, dimensions (inscribed circle diameter, thickness, nose radius, hole diameter), material types (carbide, cermet), and coating status (PVD coated or non-coated). Availability is indicated by symbols: ● (stocked), − (not manufactured), △ (made-to-order after stock depletion or after January 2011), and no mark (manufactured on request). This supports procurement planning and inventory management.

Critical Information and Best Practices

• Insert corner angles range from 35° to 360°, affecting cutting geometry and application.
• Chip breakers are matched to cutting depths: finishing (<1 mm), semi-finishing (0.5–1.5 mm), medium (1.5–4 mm), roughing (>4 mm).
• Feed rates and depths of cut are tabulated per breaker and material combination for optimal performance.
• Material grades and coatings are selected to balance wear resistance, toughness, and cutting efficiency.
• Coating thickness and composition directly influence durability and cutting performance.
• Substrate hardness and toughness must align with cutting conditions (continuous vs. interrupted).
• Physical properties such as hardness, strength, thermal conductivity, and expansion guide insert selection.
• Insert geometry, including clearance angles and chip breaker design, impacts machining efficiency and chip control.
• Cross-manufacturer grade equivalences enable flexible sourcing and application.
• Stock status symbols are essential for procurement planning to avoid delays.

Recommendations

• Select inserts based on machining requirements, material compatibility, and desired surface finish.
• Use coated inserts (PVD or CVD) for enhanced wear resistance in demanding operations.
• Refer to chip breaker codes and cutting condition tables to optimize chip control and tool life.
• Verify stock availability before ordering to ensure timely delivery.
• Plan for transition items marked with △ as they may shift to made-to-order status, affecting lead times.

Conclusion

This document serves as a comprehensive technical reference and catalog for turning inserts, providing detailed specifications, material and coating information, cutting conditions, and availability status. It supports informed tooling decisions to enhance machining efficiency, tool life, and product quality across a wide range of materials and cutting applications.