Kyocera DCMT070204GK CA4515 TJH01806 Positive Turning Insert
- Stock: In Stock
- Model: CA4515
- Weight: 0.10kg
- Manufactured: In Japan
- Ships: Worldwide
- Item Code: TJH01806
Product Overview
The DCMT070204GK CA4515 (TJH01806) is a premium-grade indexable carbide insert manufactured by Kyocera Corporation, Japan. Designed for precision finishing, this single-sided insert combines a fine-grain carbide substrate with an advanced pvd multi-layer coating to deliver exceptional performance in modern CNC turning centers.
With its 55° rhombic geometry and 7° (positive) clearance angle, the DCMT070204GK ensures stable cutting action, superior chip evacuation, and extended tool life across a broad spectrum of ferrous materials. The 0.4 mm nose radius provides the ideal balance between edge strength and surface finish quality, making this insert a versatile choice for both job shops and high-volume production facilities.
ISO Designation Breakdown
The DCMT070204GK designation follows the ISO 1832 standard for indexable inserts. Each character conveys critical geometric and tolerance information:
| Position | Code | Meaning |
|---|---|---|
| Shape | D | 55° Rhombic |
| Clearance | C | 7° (Positive) |
| Tolerance | M | ±0.13mm (M-class) |
| Fixing / Hole | T | Cylindrical hole + countersink + chip grooves (T-class) |
| Cutting Edge | 07 | Inscribed Circle ≈ 7.94 mm |
| Thickness | 02 | Insert Thickness ≈ 2.38 mm |
| Nose Radius | 04 | Corner Radius = 0.4 mm |
| Chipbreaker | GK | General / Medium (GK) profile |
Engineering Dimensions & Geometry
| Parameter | Value | Notes |
|---|---|---|
| Inscribed Circle (IC) | 7.94 mm | Nominal diameter over cutting edges |
| Insert Thickness (S) | 2.38 mm | Measured at center hole |
| Nose Radius (r) | 0.4 mm | Corner radius for edge strength |
| Cutting Edge Length | ≈ 7.9 mm | Effective engaged length |
| Inscribed Circle Diameter | 7.94 mm | ISO reference diameter |
| Clearance Angle | Positive | Relief angle between flank and workpiece |
| Tolerance Class | M | Dimensional accuracy per ISO 1832 |
| Hole Diameter | Standard ISO | Compatible with standard clamp pins |
| Countersink Diameter | Standard ISO | For screw-clamp and lever-lock systems |
| Overall Shape | 55° Rhombic | Determines approach angle and versatility |
Grade Details – Key Grade Characteristics
The CA4515 grade is a high-performance PVD-coated carbide specifically developed for steel and stainless steel machining. Its multi-layer architecture delivers a unique combination of hardness, toughness, and thermal stability.
| Characteristic | Specification |
|---|---|
| Grade Designation | CA4515 |
| Coating Technology | PVD Multi-layer |
| Coating Color | Bronze-Gold |
| Carbide Substrate | Fine-grain Carbide |
| Grain Size | Sub-micron (≈0.8 µm) |
| Coating Layers | TiAlN + TiN multi-layer |
| Coating Thickness | ≈ 3–4 µm |
| Hardness (HV) | 1,650 ± 100 |
| Transverse Rupture Strength | ≥ 2,800 MPa |
| Thermal Stability | Up to 900°C |
| Oxidation Resistance | Excellent up to 850°C |
| Friction Coefficient | 0.35–0.45 (vs. steel) |
| ISO Application Range | P15–P25 / M15–M25 / K20–K30 |
| Primary Materials | Carbon Steel, Alloy Steel, Stainless Steel, Cast Iron |
| Machining Type | Continuous to Light Intermittent |
Grade Comparison Matrix
Selecting the correct grade is critical for maximizing productivity and tool life. The following matrix compares CA4515 with adjacent Kyocera grades to guide your selection:
| Grade | Coating | Substrate | Application | Speed Range | Best For |
|---|---|---|---|---|---|
| CA4515 | PVD TiAlN | Fine-grain WC | P15–P25 / M15–M25 | Medium–High | Steel, SS, CI |
| CA4105 | PVD TiAlN | Ultra-fine WC | P10–P20 | High | Finish steel |
| CA5305 | PVD TiAlN | Sub-micron WC | P20–P30 | Medium | General steel |
| CA6515 | CVD TiC+Al₂O₃ | Medium WC | P30–P40 | Low–Medium | Roughing steel |
Chipbreaker Profile
The chipbreaker geometry on the DCMT070204GK directly influences chip formation, evacuation, and surface integrity. For this specific variant, the following profile applies:
| Attribute | Details |
|---|---|
| Chipbreaker Code | GK |
| Profile Name | General / Medium (GK) |
| Rake Angle | Positive (optimized for material group) |
| Land Width | 0.10–0.20 mm (depending on insert size) |
| Groove Depth | Shallow to medium |
| Groove Geometry | Ground periphery + medium groove |
| Chip Control | Excellent for continuous and light interrupted cuts |
| Best Application | Medium cutting and semi-roughing |
| Feed Range | 0.05–0.15 mm/rev |
| Depth of Cut Range | 0.1–1.0 mm |
Recommended Applications & Workpiece Materials
The CA4515 grade combined with the DCMT070204GK geometry is optimized for the following material groups and machining scenarios:
| Material Group | Machinability | Recommended Vc (m/min) | Notes |
|---|---|---|---|
| Carbon Steel (C45, C50) | ★★★★★ | 200–300 | Optimal chip formation |
| Alloy Steel (4140, 4340) | ★★★★☆ | 200–300 | Good edge stability |
| Stainless Steel (304, 316) | ★★★★☆ | 180–270 | Use coolant recommended |
| Cast Iron (GG25, GGG40) | ★★★★☆ | 200–300 | Dry or MQL machining |
| Tool Steel (H13, D2) | ★★★☆☆ | 160–250 | Reduced speed for hardness |
| Titanium Alloys | ★★☆☆☆ | 30–60 | Special coolant required |
Application Map by Operation
This insert is suitable for a range of CNC turning operations. The suitability matrix below helps you identify the best use cases:
| Operation | Suitability | Recommended ap (mm) | Recommended fn (mm/rev) |
|---|---|---|---|
| External Turning | ★★★★★ | 0.1–1.0 | 0.05–0.15 |
| Internal Turning | ★★★★★ | 0.1–1.0 | 0.05–0.15 |
| Face Turning | ★★★★☆ | 0.1–1.0 | 0.05–0.15 |
| Grooving | ★★★☆☆ | 0.5–2.0 | 0.10–0.20 |
| Profiling | ★★★★☆ | 0.5–2.0 | 0.10–0.25 |
| Threading | ☆☆☆☆☆ | — | — |
Recommended Cutting Conditions
Optimal cutting parameters maximize tool life and productivity. The following ranges are recommended for the DCMT070204GK CA4515 when machining steel alloys under stable conditions:
| Parameter | Symbol | Recommended Range | Unit |
|---|---|---|---|
| Cutting Speed | Vc | 200–300 | m/min |
| Feed Rate | fn | 0.05–0.15 | mm/rev |
| Depth of Cut | ap | 0.1–1.0 | mm |
| Cutting Temperature | T | 600–850 | °C |
| Coolant Pressure | P | 5–15 | bar |
| Coolant Type | — | Water-soluble emulsion / MQL | — |
Note: Reduce cutting speed by 15–20% for interrupted cuts or work-hardened materials. Increase speed by 10% for continuous, stable cuts with rigid setup.
Operating Guidelines
To achieve the best results and maximum tool life from your DCMT070204GK CA4515 inserts, follow these professional guidelines:
- Machine Rigidity: Ensure minimal spindle runout and rigid toolholder clamping. Excessive vibration accelerates flank wear and can cause catastrophic edge failure.
- Coolant Application: Apply coolant directly to the cutting zone. For CA4515, high-pressure coolant (70–100 bar) is recommended for deep-hole and internal turning applications.
- Entry Strategy: Use a ramp or arc entry rather than plunging directly into the workpiece. This reduces thermal shock and mechanical impact on the cutting edge.
- Chip Management: Verify chip evacuation regularly. Long, stringy chips indicate insufficient feed or incorrect chipbreaker selection. Adjust parameters accordingly.
- Edge Inspection: Inspect inserts after each shift for flank wear (VB), crater wear, or chipping. Replace when VB exceeds 0.3 mm or when surface finish degrades.
- Workpiece Preparation: Minimize scale, forging skin, or casting skin before machining. Hard surface layers increase notch wear and reduce insert life.
- Speed & Feed Balance: Maintain a balanced ratio between Vc and fn. Excessive speed with low feed causes crater wear; low speed with high feed causes edge chipping.
Toolholder Compatibility
The DCMT070204GK conforms to ISO standard dimensions and is compatible with a wide range of toolholders. Ensure your holder matches the insert shape, size, and clamping style for safe, efficient operation.
| Compatibility Aspect | Details |
|---|---|
| ISO Holder Designation | SDJCR/L |
| Compatible Holder Types | SDJCR/L (External), SDQCR/L (External), SCLCR/L (Boring) |
| Clamping Method | Screw-clamp / Lever-lock |
| Insert Seat Angle | Positive |
| Holder Material | Alloy steel, heat-treated |
| Shank Size Compatibility | Standard ISO shank sizes |
| Coolant Through Holder | Recommended for high-speed applications |
| Insert Orientation | Neutral (0°) or with appropriate lead angle |
| Max Overhang (External) | ≤ 4× shank diameter for stability |
| Max Overhang (Boring) | ≤ 3× tool diameter for rigidity |
Packaging & Ordering Information
| Item | Details |
|---|---|
| Manufacturer Part Number (MPN) | TJH01806 |
| Kyocera Grade | CA4515 |
| ISO Model | DCMT070204GK |
| Standard Pack Quantity | 10 inserts per pack |
| Packaging Type | Sealed plastic box with foam insert |
| Label Information | Grade, model, batch code, barcode |
| Storage Conditions | Dry environment, avoid condensation |
| Shelf Life | Indefinite when sealed; inspect after 3 years |
| Minimum Order Quantity | 1 pack (10 inserts) |
| Bulk Pricing | Available for quantities ≥ 50 packs |
| Current Unit Price | $4.7 USD per insert |
| Warranty | Full manufacturer defect warranty |
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