HPC in PERFECTION INNOVATIVE VIBRATION DAMPING SYSTEM WORLD INNOVATION. e ocut INOX STEEL

Transcription

1 INNOVATIVE VIBRATION DAMPING SYSTEM WORLD INNOVATION e ocut STEEL INOX

2 Introduction Introduction At milling with HPC-strategy beside high forces also vibrations arise. These have a negative effect on life of cutting edges and result a preterm wear of the milling tool. With the Vibcut technology we succeeded to revolutionize the milling process. Now, the vibrations are going to be absorbed directly on the origin during the stock removal process under full cutting conditions in extreme depths, as well as during small fi nishing works. Besides damping of vibrations the cutting edges are additionally protected against impacting forces. From this follows that the cutting edges of the Vibmill -milling tool keep their form even longer also under extreme milling conditions. Have fun in optimizing your milling process with Vibmill. 5 steps to get success steps to get success 5 1. Process safety - Protection of cutting edges against vibrations and impacting forces - Controlled process for manned and unmanned processing 2. Productivity - Less machine shutdowns by higher tool life - Up to 50% higher wastage rate - Dimensionally stable milling 3. User friendliness - Roughing and fi nishing process with only 1 tool - Cutting data according to spreadsheet with variable fz-values 4. Time saving - High productivity - Lower pioneering costs, thanks to detailed cutting value recommendations 5. Service - Individual consulting and fi rst training by the distribution partner - Regrinding-Service Vibcut Leads and supports you easily through the milling process Process safety Productivity User friendliness Time saving Service Cost savings with Vibcut 2

3 tools The tools The Vibmill STEEL NanoBlack Resistant material layer Vibmill INOX NanoSilver Resistant material layer Optimized chipping space for highest stability and chip transport Vibcut System Usable length (AP) Specifi c cutting geometry for highest performance of Vibcut System Function of Vibcut System Function The Vibcut System tangents the raw material of the component part to be processed and absorbs the developed vibrations Entry of the cutting edge into the material 2. Chip formation 3. Affecting of the Vibcut System on the component part 3

4 of use Area of use Area Process Rouging and fi nishing process Strategies Full section, edging, trochoidal processing and plunge milling Branches General machine building industry, medical engineering, automotive industry, aerospace technology, tool and mould making industry of Vibcut Basics of Vibcut Basics 1. Contacting of the Vibcut System on the component part removes vibrations 2. Rectangular and tangential start-up process permanent fz= 0.5-1xd* 3. Finishing ae= 0.5-1xd same fz value* 4. Finishing ae=0-0.5xd variable fz value* 5. Ae-values between the indicated values on the fz-spreadsheet will be averaged 6. Undefi ned, different material additions in a milling path fz=0.5-1xd* 7. In general we recommend to mill with the fz-value 0,5-1xd. To exhaust the full potential of the Vibmill Milling tool the variable fz-values have to be used (see processing example on page 5) *see fz-spreadsheet of tool life Comparison of tool life Comparison Processing: Roughing Tool:, z=4 Vibmill INOX,, z=4 Competitor 1 Asia, z=4 Competitor 2 Europe Material: vc: 80 m/min fz: ae: 10mm ap: 10mm Machine: Micron UCP 600 Clamping nut: Shrink fi t chuck HSK A63 Cooling: Emulsion endurances in % Competitor 1 Competitor 2 Vibmill 4

5 Processing example with variable fz-values 2 Processing example with variable fz-values 5 D 1 Tool: Vibmill STEEL No. of teeth: 4 Material: 42CrMo4 Vc: 160m/min Feed: gem. fz-tabelle Machine: DMU 60T Cooling: Emulsion C Ø 16 I t F G E 16 H 3 B A 8 Milling path Component part Milling tool t Start-up process Edging Grooving Edging Helix A: rectangular start-up process = 1xd fz=0.055* Attention!!! Rectangular or tangential start-up process max. fz=0.5-1xd B: ae=3mm equivalent to 0.3xd fz=0.052* C: ae=2mm equivalent to 0.2xd fz=0.059* D: ae=5mm equivalent to 0.5xd fz=0.047* E: ae=1mm equivalent to 0.1xd fz=0.079* F: ae=10mm equivalent to 1xd fz=0.047* G: ae=6mm equivalent to 0.6xd fz=0.047* H: ae=1mm equivalent to 0.1xd fz=0.079* I: ae=10mm equivalent to 1xd fz=0.047* Attention!!! Helix-processing max. fz=0.5-1xd Note: ae-values between the indicated values on the fz-spreadsheet will be averaged *see fz-spreadsheet Vf = n x fz x z n = 1000 x Vc x D 0,200 0,190 0,180 0,170 0,160 0,150 0,140 STEEL 0,130 0,120 0,110 0,100 0,090 0,080 0,070 0,060 0,050 0,040 0,030 0,020 0,010 0,000 1xØ-0.5xØ 0.4xØ 0.3xØ 0.2xØ 0.1xØ 0.05xØ Steel fz 0,024 0,024 0,026 0,030 0,039 0,054 Steel fz 0,032 0,032 0,034 0,039 0,054 0,073 Steel fz 0,047 Steel fz 0,055 0,056 0,060 0,069 0,092 0,127 Steel fz 0,063 0,064 0,069 0,079 0,105 0,145 Steel fz 0,079 0,080 0,086 0,099 0,132 0,182 Zustellung in % zu D fz fz (feed (Vorschub per pro teeth) Zahn) fz-diagram STEEL ae (finishing) 5

6 STEEL d1 STEEL 35 Stahl steel nano Black TM l2 Ød1 Mill-Ø Ød2 Shank-Ø L2 lenght of cut L1 overall lenght protection chamfer Ø d3 AP no. of teeth Art.-no. Price/pce. EURO AP d3 l , , , , , ,90 d2 STEEL World innovation innovation World 0,200 0,190 0,180 0,170 0,160 0,150 0,140 0,130 0,120 0,110 0,100 0,090 0,080 0,070 0,060 0,050 0,040 0,030 0,020 0,010 0,000 1xØ-0.5xØ 0.4xØ 0.3xØ 0.2xØ 0.1xØ 0.05xØ Steel fz 0,024 0,024 0,026 0,030 0,039 0,054 Steel fz 0,032 0,032 0,034 0,039 0,054 0,073 Steel fz 0,047 Steel fz 0,055 0,056 0,060 0,069 0,092 0,127 Steel fz 0,063 0,064 0,069 0,079 0,105 0,145 Steel fz 0,079 0,080 0,086 0,099 0,132 0,182 ae (Seitenzustellung) (finishing) fz (Vorschub (feed per teeth) pro Zahn) fz-diagramm STEEL 6

7 INOX INOX d1 nano Silver TM l2 Ød1 Mill-Ø Ød2 Shank-Ø L2 lenght of cut L1 overall lenght protection chamfer Ø d3 AP no. of teeth Art.-no. Price/pce. EURO AP d3 l , , , , , ,90 d2 INOX World innovation innovation World fz-diagramm INOX 0,18 0,17 0,16 0,15 0,14 0,13 0,12 0,11 0,1 0,09 0,08 0,07 0,06 0,05 0,04 0,03 0,02 0,01 0 1xØ-0.5xØ 0.4xØ 0.3xØ 0.2xØ 0.1xØ 0.05xØ Inox fz D6 0,024 0,024 0,026 0,03 0,039 0,054 Inox fz D8 0,032 0,032 0,034 0,039 0,053 0,073 Inox fz D10 0,039 0,04 0,043 0,049 0,066 0,091 Inox fz D12 0,047 Inox fz D16 0,055 0,056 0,06 0,069 0,092 0,127 Inox fz D20 0,071 0,072 0,077 0,089 0,118 0,163 ae ae (finishing) (Seitenzustellung) fz (feed (Vorschub per teeth) pro Zahn) 7

8 fz (Vorschub pro Zahn) 0,200 0,190 0,180 0,170 0,160 0,150 0,140 0,130 0,120 0,110 0,100 0,090 0,080 0,070 0,060 0,050 0,040 0,030 0,020 0,010 0,000 fz-diagram STEEL 1xØ-0.5xØ 0.4xØ 0.3xØ 0.2xØ 0.1xØ 0.05xØ Steel fz 0,024 0,024 0,026 0,030 0,039 0,054 Steel fz 0,032 0,032 0,034 0,039 0,054 0,073 Steel fz 0,047 Steel fz 0,055 0,056 0,060 0,069 0,092 0,127 Steel fz 0,063 0,064 0,069 0,079 0,105 0,145 Steel fz 0,079 0,080 0,086 0,099 0,132 0,182 ae (Seitenzustellung) fz (Vorschub pro Zahn) 0,18 0,17 0,16 0,15 0,14 0,13 0,12 0,11 0,1 0,09 0,08 0,07 0,06 0,05 0,04 0,03 0,02 0,01 0 fz-diagram INOX 1xØ-0.5xØ 0.4xØ 0.3xØ 0.2xØ 0.1xØ 0.05xØ Inox fz D6 0,024 0,024 0,026 0,03 0,039 0,054 Inox fz D8 0,032 0,032 0,034 0,039 0,053 0,073 Inox fz D10 0,039 0,04 0,043 0,049 0,066 0,091 Inox fz D12 0,047 Inox fz D16 0,055 0,056 0,06 0,069 0,092 0,127 Inox fz D20 0,071 0,072 0,077 0,089 0,118 0,163 ae (Seitenzustellung) vc-tabelle Werkstoffbezeichnung Description of material Festigkeit Strength (Nm/mm) vc (m/min) Allgemeine Baustähle General structural steels < Allgemeine Baustähle General structural steels Automatenstähle Free cutting steels < Automatenstähle Free cutting steels Unlegierte Vergütungsstähle Non-alloyed heat-treated steels < Unlegierte Vergütungsstähle Non-alloyed heat-treated steels Unlegierte Vergütungsstähle Non-alloyed heat-treated steels Legierte Vegütungsstähle Alloyed heat-treated steels Legierte Vergütungsstähle Alloyed heat-treated steels Unlegierte Einsatzstähle Non-alloyed case-hardened steels Legierte Einsatzstähle Alloyed case-hardened steels < Legierte Einsatzstähle Alloyed case-hardened steels > Werkzeugstähle Tool steels < Werkzeugstähle Tool steels Werkzeugstähle Tool steels Rostfreie Stähle, geschwefelt Rust-proof steels, sulfurated < Rostfreie Stähle, austenitisch Rust-proof steels, austenitic < Rostfreie Stähle, austenitisch Rust-proof steels, austenitic < Rostfreie Stähle, martensitisch Rust-proof steels, martensitic < Gusseisen Cast iron <180HB 160 Gusseisen Cast iron >180HB 145 Gusseisen(GGG,GT) Cast iron (GGG, GT) >180HB 120 Gusseisen(GGG,GT) Cast iron (GGG, GT) >260HB 100 Titan, Titanlegierung Titanium, titanium alloys > Titan, Titanlegierung Titanium, titanium alloys Inovatools Eckerle & Ertel GmbH Im Hüttental 3 D Kinding-Haunstetten Phone : +49 (0) 8467/ Fax: +49 (0) 8467/796 info@inovatools.eu