Kyocera DNMG110404GP CA515 TAB01900 Insert - General Finishing

Product Overview

The DNMG110404GP CA515 TAB01900 is a premium indexable turning insert manufactured by Kyocera in Japan. Designed for general finishing, this 55° diamond insert combines a cermet (TiCN-based) substrate with a PVD multi-layer (TiAlN/TiN) coating to deliver exceptional performance in steel machining applications. The GP – General Purpose geometry ensures optimal chip formation and surface integrity under general finishing and semi-finishing conditions.

With a nose radius of 0.04 mm and thickness of 4.76 mm, this insert is ideal for operations requiring very good surface finishes and dimensional accuracy within tight tolerances. The insert is fully compatible with standard ISO toolholders and delivers consistent, repeatable results across high-volume production environments.

ISO Designation Breakdown

Every position in the DNMG110404GP designation carries critical geometric and functional information per ISO 1832:2017:

Engineering Dimensions & Geometry

The following dimensional specifications define the insert's physical envelope and mounting interface:

Key geometric notes: The 0° clearance angle minimizes rubbing on the machined surface, while the 0.04 mm nose radius balances surface finish quality with tool strength. The center hole accommodates a clamping screw of 4.4 mm diameter for secure retention in the toolholder pocket.

Grade Details – Key Grade Characteristics

CA515 is a cermet (TiCN-based) grade with a PVD multi-layer (TiAlN/TiN) coating. The gold-bronze coating color indicates TiAlN-rich outer layers optimized for high-temperature stability and reduced diffusion wear.

• Hardness: HRA 92.5 – ensures excellent edge retention at elevated cutting temperatures.
• Transverse Rupture Strength: 2,200 MPa – provides adequate mechanical integrity for finishing to medium-duty applications.
• Coating Color: Gold-Bronze – visual indicator of TiAlN/TiN layer structure.
• Primary Applications: Steel (P01–P20), Stainless steel finishing, Cast iron finishing.

Performance characteristics:

• Exceptional wear resistance in high-speed finishing
• Superior chemical stability at elevated temperatures
• Low coefficient of friction for reduced built-up edge
• Excellent edge integrity for precision machining
• Optimized for continuous and light interrupted cuts

Grade Comparison Matrix

Selecting the correct grade is essential for balancing productivity, tool life, and surface quality. The matrix below positions CA515 relative to adjacent grades in the Kyocera portfolio:

Selection guidance: CA515 excels where surface finish and cutting speed are prioritized over heavy interrupted-cut toughness. For roughing or scale-covered workpieces, consider CA530. For stainless steel mirror finishing, PR930 is the recommended alternative.

Chipbreaker Profile

The GP chipbreaker on this insert is engineered specifically for general finishing and semi-finishing.

Chip control behavior: At the recommended feed rates, the GP groove produces tightly curled chips that evacuate safely away from the cutting zone. The groove land width is tuned to the 0.04 mm nose radius, ensuring consistent chip breaking across the entire cutting edge engagement length.

Recommended Applications & Workpiece Materials

The DNMG110404GP CA515 is optimized for the following material groups and machining scenarios:

• Carbon Steels (C15–C60): Excellent for finish turning and semi-finishing. Produces very good surface finishes without additional polishing.
• Alloy Steels (4140, 4340, 8620): High wear resistance maintains edge sharpness through long cuts. Ideal for shaft and bearing seat machining.
• Stainless Steels (304, 316, 420): Low affinity coating minimizes built-up edge. Use reduced speeds compared to carbon steel.
• Cast Irons (GG25, GGG40): Good performance in dry machining. The cermet substrate resists abrasive wear from graphite and carbide phases.
• Free-Cutting Steels (11SMn30, 12L14): Outstanding chip control due to the GP chipbreaker geometry. Prevents bird-nesting in automatic lathes.

Application Map by Operation

This insert's suitability across common turning operations is summarized below:

Recommended Cutting Conditions

The following parameters serve as starting points for stable, productive machining. Adjust based on machine rigidity, workpiece condition, and required surface quality:

Important notes: For alloy steels above 45 HRC, reduce cutting speed by 15–20%. When using minimal quantity lubrication (MQL), increase feed by 10% to maintain chip thickness. For cast iron with chilled edges or sand inclusion, reduce depth of cut to the lower end of the range.

Operating Guidelines

• Tool Overhang: Minimize overhang to maintain rigidity. For internal turning, use the shortest possible boring bar.
• Runout: Ensure spindle runout is below 0.01 mm to prevent uneven wear and chipping.
• Coolant Delivery: Direct coolant to the cutting zone with a pressure of at least 5 bar for effective chip evacuation and thermal management.
• Edge Preparation: Do not re-sharpen or re-coat. CA515 inserts are designed as single-use precision tools.
• Insert Change: Replace when flank wear exceeds 0.15 mm or when surface finish degrades below specification.
• Storage: Keep inserts in original packaging until use. Avoid exposure to corrosive environments or direct sunlight.

Toolholder Compatibility

The DNMG110404GP conforms to ISO standard dimensions and is compatible with the following toolholder families:

Mounting note: Use a torque wrench set to 2.5 N·m for size 07 inserts and 4.0 N·m for size 11 inserts. Over-tightening can distort the insert seat; under-tightening risks insert movement and vibration.

Packaging & Ordering Information

Catalog Meta Data