MECAMAX®AV

SIDENOR Optimises High Cutting

Speed Machining

What are MECAMAX AV steels?

MECAMAX AV are Ca treated steels (wire addition, 10-40
ppm) and resulphurised (0.020 - 0.040 % S) steels.This technology
is applicable to all Engineering steel grades (Case Hardening,
Quench & Tempered, ...) without detriment to the mechanical
properties of the final components produced out of them.

What is the use of MECAMAX AV

steels?
These grades are designed for both forged and rolled products
whose shape is produced by machining under very demanding
conditions such as high cutting speeds or rough turning and
cutting conditions.
MECAMAX®AV

Advantages of MECAMAX AV steels

By using MECAMAX AV steel productivity increases between
10 and 40% are feasible , as result of minimised tool wear, when
compared with the standard steel grades.

How does MECAMAX AV improve

the machining processes?
The addition of calcium in the liquid steel permits the removal
of most hard abrasive inclusions and the transformation of the
remnant inclusions in it. Some of them, such as aluminates and
silicates, are very hard (3000 - 4000 Hv) which leads to the
reduction of the tool life during machining operations.
The hard abrasive inclusions (Al2O3) not eliminated in the slag,
are transformed, by mean of this new technology, into softer
compounds of the Ca-Al-O kind (900-1200 Hv) and consequently
are less aggressive to machining processes.
MECAMAX®AV
Increased productivity at high cutting speeds
MECAMAX AV grades show increased machining yields at all ranges of cutting speeds (Graphic 1),
although the main advantage over standard steels is achieved at high cutting speeds (Graphic 2).

50 575
Std. HSS AV HSS 600 Turning Conditions
45
Std. Carbide P-40 AV P-40 530 No lubricant
40 550 Cutting Tool: Trip. Coat GC 4015
Std. Trip. Coat. Carbide GC-4015 AV Trip. Coat. Carbide GC-4015 Feed: 0,2 mm/rev.
480 Depth: 1 mm.
35

V20 Values ISO 3685

500
Tool life (min)

30
425
450
25
V 20 INDEX Std. AV
20 400
15 330
350
10
280
5 300

0
0 50 100 150 200 250 300 350 400 450 500 250
S355J2G3 (As rolled) 16MnCr5 (Annealed) 42CrMo4 (Q&T)
Cutting speed (m/min)
(Graphic 1). (Graphic 2).
Machining comparison C45 Std vs AV with three turning ISO 3685 Machining comparison V20 of three steels
tools at low, medium and high cutting speed. comparing Std. grades vs. their MECAMAX AV.

MECAMAX®AV
Inclusion engineering
The Calcium treatment in MECAMAX AV modifies the chemical composition of the hard abrasive
inclusions remnant in the standard grade, reducing in this way the tool wear caused by theses elements.

Al2O3 Calcium aluminates

AV Technology

High Reduction of
Tool Wear Tool Wear

SIDENOR
creates Opportunities
through Innovation

Sidenor (UK) LTD.

Northside House
Mount Pleasant, Cockfosters
Herts, EN4 9EB
United Kingdom
Tel. 44-(020)-8447 1444
Fax. 44-(020)-8447 1555
e-mail: javier_moreno@sidenor.com
www.sidenor.com
 MECAMAX®MB
SIDENOR Innovates to Optimise
Complex Cutting Operations

What are MECAMAX MB steels?

MECAMAX MB are steels with a controlled content of Bismuth
(wire addition, 0.03 - 0.08%). This technology is applicable to
all engineering steels (Case Hardening, Quench & Tempered,
...) without detriment to the mechanical properties of the final
product.

What is the use of MECAMAX MB

steels?
To ease the manufacturing of pieces with a complex geometry
that at some point will require either difficult machining at
medium and high tool speeds or more conventional machining
methods (gears, broach, drills...). These steels can be machined
MECAMAX®MB

into pieces directly from rolled bars or from forged components.

Advantages of MECAMAX MB steels

MECAMAX MB steels respect the strictest environmental
directives and produce a similar response to machining than
the equivalent leaded grades whilst maintaining the same
mechanical properties.
Efficiency increases of 40 to 60% are achieved in all cutting
operations and particularly in complex machining processes.

How does MECAMAX MB improve

the machining processes?
The addition of Bismuth allows a better lubrication of the tool
- chip interface, minimising the adhesion wear and improving
the chip fragmentation. The surface quality of the machined
components is enhanced by the better lubrication.
On addition these grades are ideally suited to the latest cutting
technologies as well as dry machining
MECAMAX®MB
High productivity in complex cutting operations
MECAMAX MB technology not only improves the efficiency of the ordinary cutting jobs (turning,
milling...), but also highly increases the efficiency of the machining of components with complex
geometry (gears, drills, broaching...). (Graphic 1).
In comparison with standard grades the dry machining or MQL (Minimum Quantity Lubrication)
operations benefit by substantially reduced cutting tool wear. (Graphic 2).

16MnCr5 Dry Machining

Turning Conditions
0,4
550 520 No lubricant
Cutting Tool: Trip. Coat GC 4015
Feed: 0,2 mm/rev. 0,35
490 Depth: 1 mm.
500 0,3
460

flank tool wear (µ)

V20 Values ISO 3685

Std. MB 0,25
450

0,2
400 375
365
0,15

350 0,1 Standard

+ Bi
275 0,05
300
0

MECAMAX®MB
250 0 200 400 600 800 1000 1200 1400
19NiCrMo2 (Annealed) C45 (As rolled) 42CrMo4 (Q&T) c.c. machined
(Graphic 1).
V20 Index (ISO 3685) Machining comparison of three (Graphic 2).
standard. grades vs.. their MECAMAX MB versions. Dry machining comparison 16MnCr5 Std vs MB.

The benefits of bismuth inclusions

Bismuth, is a chemical element that does not combine with steel but remains either as a metallic
inclusion or attached to MnS particles. The Bi low melting point and its low hardness improve the
cutting procedures by enhancing both chip fragmentation and lubricant effect, in fact at cutting
temperatures the bismuth inclusions are either gel like or even liquid.

Standard grade chip Metalic inclussion of Bi, Bi added grade chip

isoloted and attached to MnS

Machining

SIDENOR
creates Opportunities
through Innovation

Sidenor (UK) LTD.

Northside House
Mount Pleasant, Cockfosters
Herts, EN4 9EB
United Kingdom
Tel. 44-(020)-8447 1444
Fax. 44-(020)-8447 1555
e-mail: javier_moreno@sidenor.com
www.sidenor.com