Series. Multi functional milling cutter for high speed & performance machining of aluminum and titanium alloys. TOOLS NEWS

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1 TOOLS NEWS For Machining of Aluminium and Titanium Alloys AXD Series Update B116G Series Expansion Multi functional milling cutter for high speed & performance machining of aluminum and titanium alloys.

2 For Machining of Aluminium and Titanium Alloys AXD Series Features Multi Functional Milling AXD Series for excellent multi-functional performance. zshoulder milling xramping bslotting v3d copying cpocketing AXD series can be effectively used for pocket machining without the need for a prepared hole. m Helical milling nface milling Designed for high speed, efficiency and safety At high spindle speeds the double clamping screws prevent insert displacement caused by centrifugal force. The double clamping offers both reliability and safety. displacement (!m) Conventional A Conventional B AXD4000 Displacement due to Centrifugal Force displacement after air cutting displacement (!m) AXD7000 Conventional A Conventional B <Cutting conditions> Tool : AXD A04RA AXD A03RA : XDGX175008PDFR-GL XDGX227008PDFR-GL Spindle speed : 20000min -1 (for both air cutting) 5mm Point of measurement High Spindle Speeds Possible Safe and reliable high spindle speed milling can be achieved due to the use of the double screw clamping and Mitsubishi Material s proprietary Anti Fly mechanism (Double AFI). High Balance Quality Double AFI mechanism To prevent vibration under high spindle speeds the holder is balanced to G6.3 or better at 10000min -1, according to the ISO1940 standard. (The holder is balanced without the inserts and the screws in place) 1

3 Grade Features Al-Ti-Cr-N accumulated coating series-mp6100/mp9100 PVD coatings have properties such as toughness, low coeffi cient of friction and excellent welding, wear and heat resistance. This results in tough, precision grades such as MP9120. Excellent welding resistance due to low coeffi cient of friction PVD accumulated coating Special cemented carbide substrate Multi-layering of the coating prevents any cracks penetrating through to the substrate. TOUGH-Σ Technology A fusion of the separate coating technologies; PVD and multi-layering realises extra toughness. Heat resistance Oxidation temperature (Cº) Conventional MP6100 MP Hardness (Hv) Wear resistance DLC coated LC15TF DLC coating prevents the chips from welding on the insert rake face providing improved surface fi nishes and high-effi ciency machining. LC15TF can be used for both wet and dry machining. DLC coating Coeffi cient of friction 0.1 or less Adhesion strength Good The newly developed DLC coating technology maintains the surface smoothness of the inserts. Graphical representation. Coefficient of friction Work Material Grade Measured at 600 degrees S55C SUS304 Ti-6Al-4V P Carbon Steel, Alloy Steel MP S Titanium Alloy, Heat Resistant Alloy MP Conventional TF15 (micro-grain cemented carbide) TF15 Micro-grain cemented carbide with superior resistance to wear and fracturing. TF15 ensures stable cutting and effi cient machining of aluminium alloy. The special mirror treatment on the rake face prevents chip welding for reliability and longer tool life. GM breaker AXD4000 GL,GLAbreaker AXD4000 AXD7000 Improved fracture resistance compared to GL breaker Low cutting resistance breaker emphasises the good sharpness Use of AXD4000 and AXD7000 Depth of cut AXD4000 AXD7000 Low Machine Power High 2

4 For Machining of Aluminium and Titanium Alloys MULTI FUNCTIONAL MILLING <ALUMINIUM ALLOY TO DIFFICULT-TO-CUT MATERIAL CUTTING> Finishing Roughing AXD4000 P M K N S H Fig.1 Fig.2 LH Including Flat faces ON LH ON y SHANK TYPE A B RE R LH ON AXD4000R201SA20SA a TS3SBS TKY08D MK1KS AXD4000R252SA25SA a TS3SB TKY08D MK1KS AXD4000R252SA25LA a TS3SB TKY08D MK1KS AXD4000R282SA25SA a TS3SB TKY08D MK1KS AXD4000R282SA25ELA a TS3SB TKY08D MK1KS AXD4000R322SA32SA a TS3SB TKY08D MK1KS AXD4000R322SA32LA a TS3SB TKY08D MK1KS AXD4000R352SA32SA a TS3SB TKY08D MK1KS AXD4000R352SA32ELA a TS3SB TKY08D MK1KS AXD4000R403SA32SA a TS3SB TKY08D MK1KS AXD4000R403SA42SA a TS3SB TKY08D MK1KS AXD4000R403SA32ELA a TS3SB TKY08D MK1KS AXD4000R201SA20SB a TS3SBS TKY08D MK1KS AXD4000R252SA25SB a TS3SB TKY08D MK1KS AXD4000R252SA25LB a TS3SB TKY08D MK1KS AXD4000R282SA25SB a TS3SB TKY08D MK1KS AXD4000R282SA25ELB a TS3SB TKY08D MK1KS AXD4000R322SA32SB a TS3SB TKY08D MK1KS AXD4000R322SA32LB a TS3SB TKY08D MK1KS AXD4000R352SA32SB a TS3SB TKY08D MK1KS AXD4000R352SA32ELB a TS3SB TKY08D MK1KS AXD4000R403SA32SB a TS3SB TKY08D MK1KS AXD4000R403SA42SB a TS3SB TKY08D MK1KS AXD4000R403SA32ELB a TS3SB TKY08D MK1KS (Note 1) The maximum allowable revolutions are set to ensure tool and insert stability. Before operating the tool read the operational guidance on page 18. (Note 2) When using the tool at high spindle speeds, ensure that the tool and chuck are correctly balanced. (Note 3) Note for inserts with a corner radius of 1.6 and above, as corner radius increases the and LH dimensions decrease. Clamp Torque (N m) : TS3SBS=1.5, TS3SB=1.5 Use the clamp screw by setting the bundled screw. Corner Radius Order Number Stock Number of Teeth Dimensions Max. Allowable Revolution (min -1 ) (Fig.) Clamp Screw Wrench Right hand tool holder only. Anti-seize Lubricant XDGX1750pp 3 a : Inventory maintained in Japan.

5 Fig. 1 BD Fig. 2 BD ON ON Fig. 3 ø40 KWW ø50 ø63 ø80 ø100 KWW ø125 L8 CBDP CBDP L8 CBDP L8 BD ON KWW DAH DAH CB CB CB Right hand tool holder only. Cutter Diameter Set Bolt Geometry &40 HFF08043H z z x c &50, &63 HSC10030H & H x KAPR :0 & H y ARBOR TYPE GAMP: T : GAMF: I : &125 MBA20040H c Dimensions Max. 1 Order Number Allowable Revolution RE R (kg) (min -1 ) Clamp Screw Wrench Anti-seize Lubricant AXD A02RA a TS3SB TKY08D MK1KS AXD A03RA a TS3SB TKY08D MK1KS 0.4 AXD A02RA a TS3SB TKY08D MK1KS AXD A04RA a TS3SB TKY08D MK1KS 3.2 AXD A05RA a TS3SB TKY08D MK1KS AXD4000R08005CA a TS3SB TKY08D MK1KS AXD4000R10006DA a TS3SB TKY08D MK1KS AXD4000R12507EA a TS3SB TKY08D MK1KS Corner Radius A 4.0 B 5.0 Stock Number of Teeth ON CBDP DAH BD KWW L8 CB WT 2 AXD A02RB a TS3SB TKY08D MK1KS AXD A03RB a TS3SB TKY08D MK1KS AXD A02RB a TS3SB TKY08D MK1KS AXD A04RB a TS3SB TKY08D MK1KS AXD A05RB a TS3SB TKY08D MK1KS AXD4000R08005CB a TS3SB TKY08D MK1KS AXD4000R10006DB a TS3SB TKY08D MK1KS AXD4000R12507EB a TS3SB TKY08D MK1KS (Fig.) XDGX1750pp For metric arbor Dimensions Max. 1 Order Number Allowable Revolution RE R (kg) (min -1 ) Clamp Screw Wrench Anti-seize Lubricant AXD A02RA a TS3SB TKY08D MK1KS AXD A03RA a TS3SB TKY08D MK1KS 0.4 AXD A02RA a TS3SB TKY08D MK1KS AXD A04RA a TS3SB TKY08D MK1KS 3.2 AXD A05RA a TS3SB TKY08D MK1KS AXD A05RA a TS3SB TKY08D MK1KS AXD A06RA a TS3SB TKY08D MK1KS AXD B07RA a TS3SB TKY08D MK1KS Corner Radius A B Stock Number of Teeth ON CBDP DAH BD AXD A02RB a TS3SB TKY08D MK1KS AXD A03RB a TS3SB TKY08D MK1KS 4.0 AXD A02RB a TS3SB TKY08D MK1KS AXD A04RB a TS3SB TKY08D MK1KS 5.0 AXD A05RB a TS3SB TKY08D MK1KS AXD A05RB a TS3SB TKY08D MK1KS AXD A06RB a TS3SB TKY08D MK1KS AXD B07RB a TS3SB TKY08D MK1KS (Note 1) The maximum allowable spindle speeds are set to ensure tool and insert stability. Before operating the tool read the operational guidance on page 18. (Note 2) When using the tool at high spindle speeds, ensure that the tool and arbor are correctly balanced. (Note 3) Note for inserts with a corner radius of 1.6 and above, as corner radius increases the dimension decrease. METRIC Standard 1 Clamp Torque (N m) : TS3SB=1.5 1 Use the clamp screw by setting the bundled screw. 2 WT : Tool Weight KWW L8 CB WT 2 (Fig.) XDGX1750pp 4

6 For Machining of Aluminium and Titanium Alloys INSERTS Work Material Shape P N S Steel Titanium Alloy Order Number Class Honing Stock Coated Carbide LC15TF MP6120 MP9120 TF15 Dimensions L INSL S BS RE XDGX175004PDFR-GL G F a a XDGX175008PDFR-GL G F a a XDGX175012PDFR-GL G F a a XDGX175016PDFR-GL G F a a XDGX175020PDFR-GL G F a a XDGX175024PDFR-GL G F a a XDGX175030PDFR-GL G F a a XDGX175032PDFR-GL G F a a XDGX175040PDFR-GL G F a a XDGX175050PDFR-GL G F a a XDGX175004PDER-GM G E a a XDGX175008PDER-GM G E a a XDGX175012PDER-GM G E a a XDGX175016PDER-GM G E a a XDGX175020PDER-GM G E a a XDGX175024PDER-GM G E a a XDGX175030PDER-GM G E a a XDGX175032PDER-GM G E a a XDGX175040PDER-GM G E a a XDGX175050PDER-GM G E a a XDGX175004PDFR-GM G F a XDGX175008PDFR-GM G F a XDGX175012PDFR-GM G F a XDGX175016PDFR-GM G F a XDGX175020PDFR-GM G F a XDGX175024PDFR-GM G F a XDGX175030PDFR-GM G F a XDGX175032PDFR-GM G F a XDGX175040PDFR-GM G F a XDGX175050PDFR-GM G F a Be careful because corner R(RE) has a different shape than machined workpiece R. When a GM breaker is recommended, stress the dimensional precision of the workpiece shape. Cutting Conditions (Guide): :Stable Cutting :General Cutting :Unstable Cutting Honing: F :Sharp E :Round BS 30 INSL Geometry L = RE S 20 y Holder And Corner Radius Combination Holder A Holder AXD4000 pppppppa AXD4000RppppppppA B Holder AXD4000 pppppppb AXD4000RppppppppB Applicable Corner R (RE) R0.4 R0.8 R1.2 R1.6 R2.0 R2.4 R3.0 R3.2 R4.0 R5.0 XDGX XDGX XDGX XDGX XDGX XDGX XDGX XDGX XDGX XDGX PDpR-pp PDpR-pp PDpR-pp PDpR-pp PDpR-pp PDpR-pp PDpR-pp PDpR-pp PDpR-pp PDpR-pp Not interchangeable with the corresponding inserts of the A type and B type holders. 5 a : Inventory maintained in Japan. (10 inserts in one case)

7 AXD4000 Selection of insert It is necessary to choose the best insert according to the cutting conditions. Please select an insert from the tables below. 1st recommendation for stable cutting condition is the GL breaker with a strong cutting edge. Selection of insert according to the feed per tooth and the required cutting depth Selection of insert according to the width of cut and the required cutting depth ap 15 ae D ap GM breaker GL breaker 3D/4 10 GM breaker GL breaker 5 D/ fz(mm/t) 0 D/2 1st recommendation for machining aluminium alloys is GL breaker. Under high-load conditions such as deep or high feed cutting, it is advisable to use the GM breaker. ae Selection of insert according to cutting edge type Sharp cutting edge Sharp cutting edge PVD coating and Round-type honing GL TF15/LC15TF GM TF15 GM MP9120 Low cutting resistance Tougher cutting edge Tougher cutting edge & wear resistance Machining of diffi cult-to-cut materials & aluminium Selection of insert according to wear resistance Welding resistance GL LC15TF MQL & Dry cutting GM MP6120 MP9120 Super high speed cutting High SI (Cast aluminium) Heavy interrupted machining Wear resistance Cutting speed GL TF15 GM TF15 Fracture resistance Feed per tooth, Intermittent 6

8 For Machining of Aluminium and Titanium Alloys ycutting Speed Work Material Greade Breaker Cutting Speed vc (mm/min) P N Mild Steel (SS400, S10C etc) Carbon Steel Alloy Steel (S45C, SCM440 etc) (A6061, A7075 etc) <180HB MP6120 GM 200 (150220) HB MP6120 GM 200 (150220) Si<5% TF15 LC15TF TF15 MP9120 GL GM 1000 ( ) 1000 ( ) S (AC4B, A12, A390 etc) Titanium Alloy (Ti-6Al-4V etc) 5%<Si<10% Si>10% MP9120 GM 1000 ( ) MP9120 GM 40 (3060) P RECOMMENDED CUTTING CONDITIONS Cutting Width Depth of Cut Feed per Tooth (mm/t.) Work Material Breaker ae ap Cutting Edge Diameter 20 25, 28 32, , 63, , 125 < 5 < <0.25 < 10 < < 14.5 < < 5 < <180HB GM <0.5 < < 14.5 < <0.75 < 5 < < (Slot) < 5 < < 5 < <0.25 < 10 < < 14.5 < < 5 < HB GM <0.5 < < 14.5 < <0.75 < 5 < < (Slot) < 5 < Mild Steel (SS400, S10C etc) Carbon Steel Alloy Steel (S45C, SCM440 etc) (Note 1) The above cutting conditions are determined based on high workpiece and machine rigidity, where no vibration occurred. If vibrations occur make adjustments according to the machining conditions. (Note 2) Note, vibrations may occur in the following conditions. When using long tool overhang. When pocket machining corner radii. When the workpiece has poor clamping rigidity or when the machine rigidity or workpiece rigidity is low, vibrations can occur easily, if so, reduce cutting conditions such as width and depth of cut and feed per tooth. 7

9 N S Work Material (A6061, A7075 etc) (A6061, A7075 etc) (AC4B etc) (A12, A390 etc) Titanium Alloy (Ti-6Al-4V etc) Si<5% Si<5% 5%<Si<10% Si>10% Cutting Width Depth of Cut Feed per Tooth (mm/t.) Breaker ae ap Cutting Edge Diameter 20 25, 28 32, , 63, , 125 < 5 < 0.05 < 0.25 < 0.25 < 0.25 < 0.25 < 0.25 <0.25 < 10 < 0.05 < 0.2 < 0.2 < 0.2 < 0.2 < 0.2 < 14.5 < < 5 < 0.05 < 0.25 < 0.25 < 0.25 < 0.25 < 0.25 GL <0.5 < 10 < 0.2 < 0.2 < 0.2 < 0.2 < 0.2 < < 5 < 0.05 < 0.25 < 0.25 < 0.25 < 0.25 < 0.25 <0.75 < 10 < 0.2 < 0.2 < 0.2 < 0.2 < 0.2 < (Slot) < 5 < 0.05 < 0.25 < 0.25 < 0.25 < 0.25 < 0.25 < 5 < 0.05 < 0.35 < 0.35 < 0.4 < 0.4 < 0.4 <0.25 < 10 < 0.05 < 0.3 < 0.3 < 0.35 < 0.35 < 0.35 < 14.5 < 0.05 < 0.25 < 0.25 < 0.3 < 0.3 < 0.3 < 5 < 0.05 < 0.35 < 0.35 < 0.35 < 0.4 < 0.4 GM <0.5 < 10 < 0.3 < 0.3 < 0.3 < 0.35 < 0.35 < 14.5 < 0.2 < 0.25 < 0.25 < 0.3 < 0.3 < 5 < 0.05 < 0.3 < 0.3 < 0.3 < 0.35 < 0.35 <0.75 < 10 < 0.25 < 0.25 < 0.25 < 0.3 < 0.3 < 14.5 < 0.2 < 0.2 < 0.2 < 0.25 < 0.25 (Slot) < 5 < 0.05 < 0.25 < 0.25 < 0.3 < 0.35 < 0.35 < 5 < 0.05 < 0.35 < 0.35 < 0.4 < 0.4 < 0.4 <0.25 < 10 < 0.05 < 0.3 < 0.3 < 0.35 < 0.35 < 0.35 < 14.5 < 0.05 < 0.25 < 0.25 < 0.3 < 0.3 < 0.3 < 5 < 0.05 < 0.35 < 0.35 < 0.35 < 0.4 < 0.4 GM <0.5 < 10 < 0.3 < 0.3 < 0.3 < 0.35 < 0.35 < 14.5 < 0.2 < 0.25 < 0.25 < 0.3 < 0.3 < 5 < 0.05 < 0.3 < 0.3 < 0.3 < 0.35 < 0.35 <0.75 < 10 < 0.25 < 0.25 < 0.25 < 0.3 < 0.3 < 14.5 < 0.2 < 0.2 < 0.2 < 0.25 < 0.25 (Slot) < 5 < 0.05 < 0.25 < 0.25 < 0.3 < 0.35 < 0.35 < 5 < 0.05 <0.25 < 10 < 0.05 < 14.5 < 0.05 < 5 < 0.05 < 0.08 GM <0.5 < 10 < 0.08 < 14.5 < 0.08 < 5 < 0.05 < 0.05 < 0.08 <0.75 < 10 < 0.05 < 0.08 < 14.5 < 0.05 < 0.08 (Slot) < 5 < 0.05 < 0.05 < 0.05 < 0.05 < 0.05 < 0.05 (Note 1) The above cutting conditions are determined based on high workpiece and machine rigidity, where no vibration occurred. If vibrations occur make adjustments according to the machining conditions. (Note 2) Note, vibrations may occur in the following conditions. When using long tool overhang. When pocket machining corner radii. When the workpiece has poor clamping rigidity or when the machine rigidity or workpiece rigidity is low, vibrations can occur easily, if so, reduce cutting conditions such as width and depth of cut and feed per tooth. 8

10 For Machining of Aluminium and Titanium Alloys RAMPING/HELICAL CUTTING y a RAMPING L a HELICAL CUTTING Pitch (P) Blind holes, Flat bottom Pitch (P) Through holes RMPX L= tan % RAMPING/HELICAL CUTTING (ALUMINIUM ALLOY) Holder A type RE Hole diameter (DH) Hole diameter (DH) Ramping Helical Milling (Blind Hole, Flat Bottom) Helical Milling L RMPX 1 DH max. P max. DH min. P max. DH min. P max

11 Holder B type (Note 1) The recommended ramping feed is 0.05mm/tooth or under. 1) Using the maximum ramping angle, the distance to reach the maximum depth of cut is as follows: L= (maximum depth of cut /tan %). Maximum depth of cut A type is 15.5mm, B type is 14.8mm. 2) Corner radius of 1.2mm. For other corner radii, use the following formula. {(cutting edge diameter )(corner radius RE) 0.25} 2 3) Corner radius of 2.4mm. For other corner radii, use the following formula. {(cutting edge diameter )(corner radius RE) 0.25} 2 4) Corner radius of 3.2mm. For other corner radii, use the following formula. {(cutting edge diameter )(corner radius RE) 0.25} 2 RE Ramping Helical Milling (Blind Hole, Flat Bottom) Helical Milling L RMPX 1 DH max. P max. DH min. P max. DH min. P max. y Max.Drilling Depth (Aluninium Alloy) A type B type Max.Drilling Depth Corner R RE Cutting Edge Diameter &20 &25 &28 &32 &35 &40& AXD4000 can be effectively used for pocket machining without the need for a prepared hole. 10

12 For Machining of Aluminium and Titanium Alloys MULTI FUNCTIONAL MILLING <FOR ALUMINIUM ALLOY> Finishing Roughing AXD7000 P M K N S H y ARBOR TYPE Corner Radius RE 0.8 A B 5.0 Order Number KAPR :0 GAMP:+11 GAMF: Stock Number of Teeth T : I :+11 Fig.1 ø50 ø63 ø80 ø100 a Low resistance chipbreaker. a Low resistance insert and high rigidity design for excellent performance. a For high-speed machining. a Multi-functional machining. BD ON KWW DAH CB Dimensions WT 2 (kg) Cutter Diameter Set Bolt &50, &63 HSC10030H & H & H z &125 MBA20040H x AXD A03RA a TS4SBL TKY15D MK1KS AXD7000R08004CA a TS4SBL TKY15D MK1KS AXD7000R10005DA a TS4SBL TKY15D MK1KS AXD7000R12506EA a TS4SBL TKY15D MK1KS AXD A03RB a TS4SBL TKY15D MK1KS AXD A03RB a TS4SBL TKY15D MK1KS AXD7000R08004CB a TS4SBL TKY15D MK1KS AXD7000R10005DB a TS4SBL TKY15D MK1KS AXD7000R12506EB a TS4SBL TKY15D MK1KS CBDP L8 Fig.2 ø125 CBDP L8 Including Flat faces BD ON KWW CB Right hand tool holder only. Max. Allowable Revolution (min -1 ) R ON CBDP DAH BD KWW L8 CB Clamp Screw AXD A03RA a TS4SBL TKY15D MK1KS (Fig.) 1 Geometry z Wrench Anti-seize Lubricant x XDGX2270pp ON y SHANK TYPE A B AXD7000R402SA42SA a TS4SBL TKY15D MK1KS AXD7000R322SA32SB a TS4SB TKY15D MK1KS 5.0 AXD7000R402SA42SB a TS4SBL TKY15D MK1KS (Note 1) The maximum allowable revolutions are set to ensure tool and insert stability. Before operating the tool read the operational guidance on page 18. (Note 2) When using the tool at high spindle speeds, ensure that the tool and chuck are correctly balanced. (Note 3) Note for inserts with a corner radius of 3.0 and above, as corner radius increases the and LH dimensions decreases. 1 Clamp Torque (N m) : TS4SB=3.5, TS4SBL=3.5 1 Use the clamp screw by setting the bundled screw. 2 WT : Tool Weight Stock Number of Teeth Max. Corner Dimensions Radius Order Number Allowable Revolution RE R LH ON (min -1 ) Clamp Screw Wrench Anti-seize Lubricant 0.8 AXD7000R322SA32SA a TS4SB TKY15D MK1KS LH 1 Right hand tool holder only. XDGX2270pp 11 a : Inventory maintained in Japan.

13 Fig.1 ø50 ø63 ø80 ø100 CBDP L8 BD ON KWW Fig.2 ø125 CBDP L8 BD ON KWW DAH CB Right hand tool holder only. CB For metric arbor The cutter bore diameter ON is indicated in millimetre. y ARBOR TYPE A B A Corner Radius Corner Radius KAPR :0 GAMP:+11 GAMF: y HSK63A SHANK TYPE RE Order Number T : I :+11 Dimensions WT 2 (kg) Cutter Diameter Set Bolt &50, &63 HSC10030H & H & H z &125 MBA20040H x AXD A03RA a TS4SBL TKY15D MK1KS AXD A04RA a TS4SBL TKY15D MK1KS AXD A05RA a TS4SBL TKY15D MK1KS AXD B06RA a TS4SBL TKY15D MK1KS AXD A03RB a TS4SBL TKY15D MK1KS AXD A03RB a TS4SBL TKY15D MK1KS AXD A04RB a TS4SBL TKY15D MK1KS AXD A05RB a TS4SBL TKY15D MK1KS AXD B06RB a TS4SBL TKY15D MK1KS Order Number Stock Number of Teeth Stock Number of Teeth Dimensions Max. Allowable Revolution (min -1 ) LU 1 Geometry z x XDGX2270pp HSK63A ø63 Right hand tool holder only. RE R LU Clamp Screw Wrench Anti-seize Lubricant 0.8 AXD7000R03202A-H63A a TS4SB TKY15D MK1KS AXD7000R04002A-H63A a TS4SBL TKY15D MK1KS XDGX2270pp 3.2 AXD7000R05003A-H63A a TS4SBL TKY15D MK1KS (Note 1) The maximum allowable revolutions are set to ensure tool and insert stability. Before operating the tool read the operational guidance on page 18. (Note 2) When using the tool at high spindle speeds, ensure that the tool and arbor are correctly balanced. (Note 3) Note for inserts with a corner radius of 3.0 and above, as corner radius increases the and LU dimensions decreases. (Note 4) No hole for data carrier. 1 Clamp Torque (N m) : TS4SB=3.5, TS4SBL=3.5 1 Use the clamp screw by setting the bundled screw. 2 WT : Tool Weight Max. Allowable Revolution (min -1 ) R ON CBDP DAH BD KWW L8 CB Clamp Screw AXD A03RA a TS4SBL TKY15D MK1KS (Fig.) 1 Wrench Anti-seize Lubricant 12

14 For Machining of Aluminium and Titanium Alloys INSERTS Work Material Shape P N S Steel Titanium Alloy Order Number Class Honing Stock Coated Carbide LC15TF MP6120 MP9120 TF15 Cutting Conditions (Guide): :Stable Cutting :General Cutting :Unstable Cutting Honing: F :Sharp E :Round Dimensions L INSL S BS RE XDGX227008PDFR-GL G F a a XDGX227016PDFR-GL G F a a XDGX227020PDFR-GL G F a a XDGX227024PDER-GL G F a a XDGX227030PDFR-GL G F a a XDGX227032PDFR-GL G F a a XDGX227040PDFR-GL G F a a XDGX227050PDFR-GL G F a a XDGX227008PDER-GLA G E a a XDGX227016PDER-GLA G E a a XDGX227020PDER-GLA G E a a XDGX227024PDER-GLA G E a a XDGX227030PDER-GLA G E a a XDGX227032PDER-GLA G E a a XDGX227040PDER-GLA G E a a XDGX227050PDER-GLA G E a a GLA breaker corner R (RE) is designed with almost same corner R as a mechined corner R of workpiece. Be careful because corner R (RE) has a different shape machined workpiece R. BS 30 INSL Geometry L = RE S 20 yholder AND INSERT CORNER RADIUS COMBINATION Holder Corner Radius (RE) A Holder AXD7000 pppppppa AXD7000RppppppppA AXD7000RppppA-H63A XDGX PDFR-Gp B Holder AXD7000 pppppppb AXD7000RppppppppB R0.8 R1.6 R2.0 R3.0 R3.2 R4.0 R5.0 XDGX PDFR-Gp XDGX PDFR-Gp XDGX PDFR-Gp XDGX PDFR-Gp Not interchangeable with the corresponding inserts of the A type and B type holders. XDGX PDFR-Gp XDGX PDFR-Gp 13 a : Inventory maintained in Japan. (10 inserts in one case)

15 ycutting Speed Work Material Greade Breaker Cutting Speed vc (mm/min) P N Mild Steel (SS400, S10C etc) Carbon Steel Alloy Steel (S45C, SCM440 etc) (A6061, A7075 etc) <180HB MP6120 GLA 200 (150220) HB MP6120 GLA 200 (150220) LC15TF GL 1000 ( ) Si<5% TF15 GL 1000 ( ) S (AC4B, A12, A390 etc) Titanium Alloy (Ti-6Al-4V etc) 5%<Si<10% Si>10% LC15TF GL 1000 ( ) MP9120 GLA 40 (3060) P RECOMMENDED CUTTING CONDITIONS Work Material Mild Steel (SS400, S10C etc) Carbon Steel Alloy Steel (S45C, SCM440 etc) <180HB Breaker GLA HB GLA Cutting Width ae <0.25 <0.5 <0.75 (Slot) <0.25 <0.5 <0.75 (Slot) Depth of Cut Feed per Tooth (mm/t.) ap Cutting Edge Diameter , 63, , 125 < 5 8 < 0.2 < 0.2 < 0.2 < < < 20 < 5 8 < 0.2 < 0.2 < 0.2 < < < 20 < < < 15 < < < 5 8 < 0.2 < 0.2 < 0.2 < < < 20 < 5 8 < 0.2 < 0.2 < 0.2 < < < 20 < < < 15 < < (Note 1) The above cutting conditions are determined based on high workpiece and machine rigidity, where no vibration occurred. If vibrations occur make adjustments according to the machining conditions. (Note 2) Note, vibrations may occur in the following conditions. When using long tool overhang. When the workpiece has poor clamping rigidity or when the machine rigidity or workpiece rigidity is low,vibrations can occur easily, if so, reduce the cutting conditions. When pocket machining corner radii. 14

16 For Machining of Aluminium and Titanium Alloys N S RECOMMENDED CUTTING CONDITIONS Work Material (A6061, A7075 etc) (AC4B etc) (A12, A390 etc) Titanium Alloy (Ti-6Al-4V etc) Si<5% 5%<Si<10% Si>10% Breaker GL GL GLA Cutting Width ae <0.25 <0.5 <0.75 (Slot) <0.25 <0.5 <0.75 (Slot) <0.25 <0.5 <0.75 (Slot) Depth of Cut Feed per Tooth (mm/t.) ap Cutting Edge Diameter , 63, , 125 < 5 < 0.35 < 0.4 < 0.4 < 0.4 < 10 < 0.3 < 0.35 < 0.35 < 0.35 < 15 < 0.25 < 0.3 < 0.3 < 0.3 < 20 < 0.2 < 0.25 < 0.25 < 0.25 < 5 < 0.35 < 0.35 < 0.4 < 0.4 < 10 < 0.3 < 0.3 < 0.35 < 0.35 < 15 < 0.25 < 0.25 < 0.3 < 0.3 < 20 < 0.2 < 0.2 < 0.25 < 0.25 < 5 < 0.3 < 0.3 < 0.35 < 0.35 < 10 < 0.25 < 0.25 < 0.3 < 0.3 < 15 < 0.2 < 0.2 < 0.25 < 0.25 < < 0.2 < 0.2 < 5 < 0.25 < 0.3 < 0.35 < 0.35 < 10 < 0.2 < 0.25 < 0.3 < 0.3 < 15 5 < 0.2 < 0.25 < 0.25 < 20 5 < 0.2 < 0.2 < 5 < 0.35 < 0.4 < 0.4 < 0.4 < 10 < 0.3 < 0.35 < 0.35 < 0.35 < 15 < 0.25 < 0.3 < 0.3 < 0.3 < 20 < 0.2 < 0.25 < 0.25 < 0.25 < 5 < 0.35 < 0.35 < 0.4 < 0.4 < 10 < 0.3 < 0.3 < 0.35 < 0.35 < 15 < 0.25 < 0.25 < 0.3 < 0.3 < 20 < 0.2 < 0.2 < 0.25 < 0.25 < 5 < 0.3 < 0.3 < 0.35 < 0.35 < 10 < 0.25 < 0.25 < 0.3 < 0.3 < 15 < 0.2 < 0.2 < 0.25 < 0.25 < < 0.2 < 0.2 < 5 < 0.25 < 0.3 < 0.35 < 0.35 < 10 < 0.2 < 0.25 < 0.3 < 0.3 < 15 5 < 0.2 < 0.25 < 0.25 < 20 5 < 0.2 < 0.2 < 5 < 10 < 15 < 20 < 5 < 10 < 15 < 20 < 5 < 10 < 15 < 20 < 5 < 10 < 0.08 < 0.05 < 0.08 < 0.08 < 0.08 < 0.08 (Note 1) The above cutting conditions are determined based on high workpiece and machine rigidity, where no vibration occurred. If vibrations occur make adjustments according to the machining conditions. (Note 2) Note, vibrations may occur in the following conditions. When using long tool overhang. When the workpiece has poor clamping rigidity or when the machine rigidity or workpiece rigidity is low,vibrations can occur easily, if so, reduce the cutting conditions. When pocket machining corner radii. 15

17 RAMPING/HELICAL CUTTING y aramping L ahelical CUTTING Pitch (P) Through holes RMPX L= tan % RAMPING/HELICAL CUTTING (ALUNIMIUM ALLOY) A type B type RE RMPX Ramping L , , , , , , , , , , , , , , Hole diameter (DH) , , , , , , , (Note) The recommended ramping feed is 0.05mm/tooth or under. 1 L (Max. Depth of Cut =15 / tan %). Cutters' moving distance until depth of cut reaches at a maximum ramping angle. Maximum depth of cut A type is 21mm, B type is 20.4mm. 2 The maximum diameter when machining a blind hole with a fl at face using a corner radius of 0.8mm for A type and 4mm for B type. Other than that, fi nd with the below formula. {(cutting edge diameter )(corner radius)0.3)} 2 3 The minimum diameter when machining a blind hole with a fl at face using a corner radius of 0.8mm for A type and 4mm for B type. Other than that, fi nd with the below formula. {(cutting edge diameter )(corner radius)(width of wiper edge BS)0.1)} 2 A type B type RE Helical Milling DH min. P max. y Max. Drilling Depth (Alunimium Alloy) A B corner radius Max. Drilling Depth RE , AXD7000 can be effectively used for pocket machining without the need for a prepared hole. 16

18 For Machining of Aluminium and Titanium Alloys a HELICAL CUTTING Pitch (P) Blind holes, Flat bottom RAMPING/HELICAL CUTTING (ALUNIMIUM ALLOY) RE BS DH max. Hole diameter (DH) Helical Cutting (Blind Hole, Flat Bottom) 2 P max. DH min. 3 P max A type B type (Note) The recommended ramping feed is 0.05mm/tooth or under. 1 L (Max. Depth of Cut =15 / tan %). Cutters' moving distance until depth of cut reaches at a maximum ramping angle. Maximum depth of cut A type is 21mm, B type is 20.4mm. 2 The maximum diameter when machining a blind hole with a fl at face using a corner radius of 0.8mm for A type and 4mm for B type. Other than that, fi nd with the below formula. {(cutting edge diameter )(corner radius)0.3)} 2 3 The minimum diameter when machining a blind hole with a fl at face using a corner radius of 0.8mm for A type and 4mm for B type. Other than that, fi nd with the below formula. {(cutting edge diameter )(corner radius)(width of wiper edge BS)0.1)} 2 17

19 ycaution FOR USE Procedure for attaching inserts 1) Clean the seat by air blowing or with a brush before installing the insert. 2) Tighten the clamp screw using the accessory wrench while pressing the insert against the seat. 3) Tighten the clamp screw as shown in Figure 1. 4) Coat the clamp screw with anti-seize compound and tighten it to the specifi ed tightening torque. The tightening torque is shown below. AXD N m(2.58ft lb) AXD N m(1.11ft lb) 5) The clamp screw is an important part in ensuring safety. Purchase an offi cial product from Mitsubishi Materials. When using over the revolution shown in Table 2, replacing the clamp screw simultaneously with insert replacement is recommended. Cutting Edge Diameter Clamp Screw Number Overall Length L AXD4000 AXD7000 ø20 ø25 ø125 ø32 ø40 ø125 TS3SBS TS3SB TS4SB TS4SBL L Fig.1 1st 2nd 6) Check that there is no clearance at the insert seat surface. Installation of arbor type 1) Clean carefully the inside and face of the hole and the arbor face before installing the body to the arbor. 2) Set the body at the arbor and tighten it with the accessory. Refer to the table shown below for the tightening torque. 3) The set bolt supplied with the AXD is a special coolant through compatible nozzle. Be careful not to lose it. AXD4000 Fig.1 Geometry Fig.2 Fig.3 Set Bolt Clamp Torque (N m) Cutting Edge Diameter HFF08043H 11 ø40 1 HSC10030H 40 ø50, ø63 2 HSC12035H 80 ø80 2 HSC16040H 150 ø100 2 MBA20040H 320 ø120 3 AXD7000 Fig Geometry Set Bolt Fig.1 Fig.2 Clamp Torque (N m) Cutting Edge Diameter Fig HSC10030H 40 ø50, ø63 1 HSC12035H 80 ø80 1 HSC16040H 150 ø100 1 MBA20040H 320 ø120 2 Table 1 Max. Allowable Revolution AXD4000 Cutting Edge Diameter Max. Allowable Revolution (min -1 ) AXD7000 Cutting Edge Diameter Max. Allowable Revolution (min -1 ) ø25 ø32 ø40 ø50 ø63 ø80 ø100 ø ø32 ø40 ø50 ø63 ø80 ø100 ø a Even when operating under the maximum allowable spindle speed, if the spindle speed is equal to or higher than the values shown in table 2, it is recommended that the balance quality (with the arbor or milling chuck) conforms to G6.3 or betterbased on ISO1940. It is also recommended to replace the clamp screws with new ones when changing inserts. Furthermore,ensure to use machines that are provided with safety measures in case of cutter breakage. (Note) The balance quality of the holder (without inserts and clamp screws) is G6.3 or better at 10,000min -1. Table 2 Maximum spindle speed when balancing with the arbor or milling chuck has not been achieved AXD4000 Cutting Edge Diameter Max. Allowable Revolution (min -1 ) AXD7000 Cutting Edge Diameter Max. Allowable Revolution (min -1 ) ø25 ø32 ø40 ø50 ø63 ø80 ø100 ø ø32 ø40 ø50 ø63 ø80 ø100 ø a When setting the spindle speed, take into consideration the maximum allowable spindle speed of the arbor or milling chuck. a Use the specified set bolt when using the arbor type with through coolant. a The inserts have sharp cutting edges and handling them with bare hands may cause injuries. Always wear safety gloves whenhandling the indexable inserts. 18

20 For Machining of Aluminium and Titanium Alloys Technical Data Excellent Wall Accuracy Specially designed G-class inserts with a helical cutting edge for excellent wall accuracy. Depth of cut per pass δ Wall surface accuracy δ (!m) Wall surface accuracy δ (!m) Convetional tooling AXD AXD Depth of cut per pass Depth of cut per pass <Cutting conditions> <Cutting conditions> Tool : AXD4000R403SA42SA Tool : AXD7000R402SA42SA : XDGX175008PDFR-GL : XDGX227008PDFR-GL Grade : TF15 Grade : TF15 Workpiece : JIS A7075 Workpiece : JIS A7075 Cutting speed : 1000m/min Cutting speed : 2500m/min Feed per tooth Width of cut Cutting mode : 0.2mm/tooth : 3mm : Wet Feed per tooth Width of cut Cutting mode Convetional tooling : 0.2mm/tooth : 3mm : Wet Low Resistance s An optimised helical fl ank and fl ank angle offers cutting edge strength and provides a large rake angle to reduce cutting resistance. Additionally a convex cutting edge is incorporated to ensure effective chip fl ow. <Cutting conditions> Tool Grade Workpiece : AXD A04RA AXD A03RA : XDGX175008PDFR-GL XDGX227008PDFR-GL : TF15 : JIS A7075 Cutting speed : 1000m/min Feed per tooth : 0.2mm/tooth Width of cut : 25mm Depth of cut : 10mm Cutting mode : Wet Single tooth Power consumption (N) Cutting resistance AXD Competitor A Competitor B Principal force Feed force Back force Principal force Power consumption (N) AXD7000 Competitor A Competitor B Feed force Back force Convex cutting edge Helical flank Comparison of surface finishes Improved surface finishes by reducing feed mark Conventional AXD4000-GM, TF15 Cutting performance on Ti-6AL-4V Stable tool life under high-load conditions Conventional AXD4000-GM, MP9120 Ra 0.675μm Rz 3.725μm <Cutting conditions> Tool : AXD A04RA : XDGX175004PDFR-GM Grade : TF15 Workpiece : JIS A7075 Cutting speed : 1000m/min Feed per tooth : 0.15mm/tooth Ra 0.120μm Rz 1.132μm Width of cut Depth of cut Cutting mode : 30mm : 0.5mm : Wet Single tooth After 0.4m of machining <Cutting conditions> Tool : AXD A04RA : XDGX175004PDER-GM Grade : MP9120 Workpiece : Ti-6Al-4V Cutting speed : 30m/min Feed per tooth : 0.1mm/tooth After 0.8m of machining Width of cut Depth of cut Cutting mode : 40mm : 2mm : Wet (Int. and Ext.) Single tooth 19

21 Cutting Performance Cutting of aluminium alloy cast iron : Si content 9% 2.3 times longer tool life due to tougher cutting edge & PVD coating MP9120 GM breaker JL breaker Conventional Conventional Tool life (min) <Cutting conditions> Workpiece : aluminium alloy cast iron : Si content 9% Tool : AXD A02RA : XDGX175008PDER-GM Cutting speed : 960m/min Feed : 0.1mm/tooth Depth of cut : ap=6.0mm ae=33mm Cutting mode : Wet 20

22 For Machining of Aluminium and Titanium Alloys APPLICATION EXAMPLES Tool AXD A02RA (Grade) XDGX175030PDFR-GL(TF15) JIS A7075 JIS A7050 AXD4000R322SA32SA XDGX175030PDFR-GL(TF15) Workpiece Cutting Conditions Spindle speed (min -1 ) Cutting Speed (m/min) Feed per Tooth (mm/tooth) Depth of Cut 6 12 Width of Cut Metal Removal Rate (cm 3 /min) Cutting mode Wet Wet Machine Spindle M/C-HSK80F M/C-BT50 Result Tool (Grade) Although tool overhang was signifi cant, the low cutting resistance compared with conventional products enabled stable milling. JIS A5052 AXD4000R12507EA XDGX175008PDFR-GL(TF15) Compared with conventional products, tool rigidity is high, obtaining an excellent surface fi nish. JIS A7075 AXD A03RB XDGX227040PDFR-GL(TF15) Workpiece Cutting Conditions Spindle speed (min -1 ) Cutting Speed (m/min) Feed per Tooth (mm/tooth) Depth of Cut 5 18 Width of Cut Metal Removal Rate (cm 3 /min) Cutting mode 4200 Wet 9720 MQL Machine Spindle M/C-BT50 M/C-HSK63/80A Result Compared with conventional products, cutting resistance is low, and feed rate per tooth was improved by 20%. AXD displayed lower cutting resistance and achieved a high metal removal rate of up to 9720cm 3 /min. Please note that the machining performed in the application examples is dependent on the rigidity of the machine used and the rigidity of the workpiece and clamping. 21

23 Tool (Grade) JIS A7075 AXD A03RA XDGX227008PDFR-GL(TF15) JIS A7075 AXD7000R402SA42SA XDGX227008PDFR-GL(TF15) Workpiece Cutting Conditions Spindle speed (min -1 ) Cutting Speed (m/min) Feed per Tooth (mm/tooth) Depth of Cut Width of Cut 20 5 Metal Removal Rate (cm 3 /min) Cutting mode Wet Wet Machine Spindle M/C-BT50 M/C-HSK63A Result Clamping rigidity of the inserts was higher than a conventional product, thus allowing stable 5-axis machining. AXD achieved excellent results with a vertical wall accuracy of under 0.007mm. Tool (Grade) Ti-6Al-4V AXD A04RA XDGX175008PDER-GM(MP9120) AXD4000R252SA25SA XDGX175008PDER-GM(MP9120) JIS-AC4A: Si content 8-10% Workpiece Cutting Conditions Spindle speed (min -1 ) Cutting Speed (m/min) Feed per Tooth (mm/tooth) Depth of Cut Width of Cut Cutting mode Wet External coolant Machine Vertical 3 axis Vertical Result AXD achieved double tool life compared to conventional products. Aluminium alloy containing Si tends to cause tool damage, but the MP9120 inserts gave double the tool life compared to conventional grades. 22

24 AXD For Machining of Aluminium and Titanium Alloys AXD For Your Safety adon't handle inserts and chips without gloves. aplease machine within the recommended application range and exchange expired tools with new ones in advance of breakage. aplease use safety covers and wear safety glasses. awhen using compounded cutting oils, please take fire precautions. awhen attaching inserts or spare parts, please use only the correct wrench or driver. awhen using rotating tools, please make a trial run to check run-out, vibration and abnormal sounds etc. MITSUBISHI MATERIALS CORPORATION Overseas Sales Dept, Asian Region KFC bldg., 8F, Yokoami, Sumida-ku, Tokyo , Japan TEL FAX Overseas Sales Dept, European & American Region KFC bldg., 8F, Yokoami, Sumida-ku, Tokyo , Japan TEL FAX (Tools specifications subject to change without notice.) EXP-10-E E( - )