Coolant-Through, Three fluted, Carbide Drills

Transcription

1 PRODUCT INORMATION Coolant-Through, Three fluted, Carbide Drills TR-HO-3D TR-HO-5D TR-HO-10D VOL.2

2 Three concepts differentiate the TR series from two-flute & convetional drills Improved eed Rate The higher the feed rate, the more the output Reduced cost per unit Higher Precision Better tapping process from improved pilot holes Reamer-less drilling can be achieved Reduced Work Hardening Optimal conditions for thread making Improved tool life for succeeding cutting tools Higher Precision! There are 2 keys to High Precision Drilling 1. Good biting properties to minimize defl ection 2. table guide to keep the drilling process straight. 2flute drill This center This center fixes drill s entry drill s point entry 2 flute drill There is no pivotal point 2 2 Directions vs vs3 Directions!! 3 Directions WDI Coating The WDI coating is effective in high feed drilling Comparison of the amount of work hardening versus feed per revolution in carbon steel. Work hardening rate comparison Work hardening layer depth comparison TR-HO-5D TR-HO-5D Two-lute Two-lute ,22 0,32 0,43 0,65 eed Rate (mm/rev) 0 0,22 0,32 0,43 0,65 eed Rate (mm/rev)

3 Improved feed rate! If we needed to drill 10mm through hole TR will complete the process in Conventional Drill, on the other 10 revolutions with feed rate of hand, will require 100 revolutions at 1mm/rev. 0.1mm/rev feed rate 10 revolutions = 10mm 10 revolutions = 1.0mm Reduced work hardening! The cause of Many Machining Problems is Work Hardening HARDENED LAYER Work Hardening can cause : 1. Unstable tapping quality for both cutting and forming taps 2. Increased machine load that often result in reduced tool life for the drill and succeeding cutting tools. Tool TR-HO-5D ø10,8 TR-5D Two-lute Work Material 50c (DIN CK50) (AII 1050) Drilling peed 100m/min (2.950min -1 ) Work Hardening Level Work Hardening Depth Work Hardening Depth Work Hardening Depth eed Rate (Hv0,1) (μm) (Hv0,1) (μm) eed Depth of Hole Coolant Machine Variable (ee chart) 25mm (Through) Water oluble Horizontal Machining Center f=0,22mm/rev f=0,32mm/rev f=0,43mm/rev 185 6, f=0,65mm/rev These graphs shows the level and depth of work hardening in carbon steel when comparing the Mega Muscle drill versus 2 fluted drills. The amount of feed per revolution ranges from 0.22 to 0.65mm/rev. Regardless of the number of flutes, work hardening has the tendency to increase with the increase of the feed rate. It can be noted, when the same feed rate is applied to both drills, the 3 fluted type has a much lower work hardening effect. 3 fluted drills always achieve lower work hardening rates when compared to 2 fluted drills. Thus, it is best practice to keep the work hardening as low as possible when secondary operations such as tapping or reaming are required. The Mega Muscle Drill offers this process stability, reducing the burden of the taps and reamers increasing their tool life. 3

4 140 TR-HO-3D AVAILABLE IN JANUARY 2013 D p R thinning I L CARBIDE WDI 30 IT To ensure a stable fl ow of coolant, there ia groove on the bottom of the shank 140 h8 RD 4 On some drills, the coating may have some discoloration. This does not pose any performance problems. EDP D L l d tock Price EDP D L l d tock Price , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , Different diameters and lengths are available as specials. Also a special design for aluminium alloys are available upon request. Delivery from stock Available on short notice C 0.45% CM ~35 HRC 35~45 HRC 45~50 HRC 50~70 HRC U KD GG GGG Cu AI AC Ti Tiall Inc 4

5 140 TR-HO-5D AVAILABLE IN JANUARY 2013 D p R thinning I L CARBIDE WDI 30 IT To ensure a stable fl ow of coolant, there ia groove on the bottom of the shank 140 h8 RD 4 On some drills, the coating may have some discoloration. This does not pose any performance problems. EDP D L l d tock Price EDP D L l d tock Price , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , , Different diameters and lengths are available as specials. Also a special design for aluminium alloys are available upon request. Delivery from stock Available on short notice C 0.45% CM ~35 HRC 35~45 HRC 45~50 HRC 50~70 HRC U KD GG GGG Cu AI AC Ti Tiall Inc 5

6 140 TR-HO-10D AVAILABLE IN MARCH 2013 D d R thinning l L CARBIDE WDI 30 IT To ensure a stable fl ow of coolant, there ia groove on the bottom of the shank 140 h8 RD 4 On some drills, the coating may have some discoloration. This does not pose any performance problems. EDP D L l d tock Price EDP D L l d tock Price , , , , Different diameters and lengths are available as specials. Also a special design for aluminium alloys are available upon request. Delivery from stock Available on short notice C 0.45% CM ~35 HRC 35~45 HRC 45~50 HRC 50~70 HRC U KD GG GGG Cu AI AC Ti Tiall Inc 6

7 Unmatched Processing Efficiency! Drilling feeds exceeding mm/min! eed rates of = 1480mm/min were achieved in this crankshaft application (carbon steel) Tool TR-HO-3D ø 10,3 Work Material 50C Drilling peed 100m/min (2.950min -1 ) DIN CK50 [ AII 1050] Drills TR-HO-3D Number of Holes (holes) Continue eed Depth of Hole 1.480mm/min (0,5mm/rev) 24mm (Blind) 560mm/min 0,19mm/rev 1.020(holes) Wear 1,5 times the tool life 2,7 times the productivity Coolant Water oluble Machine Horizontal Machining Center Example of the hole processing for the mounting holes on the crankshaft flywheel. The Mega Muscle Drill achieved 1.5 times the tool life and 2.7 times the productivity over 's 2 fluted drill. With the ability to control work hardening, one has the ability to extend tool life on secondary processes such as tapping, thus decreasing overall tooling and part cost per unit. or example, by lowering the cutting speed to 80m/min, tool life of the drill and all secondary process tools can be extended. In the processing of carbon steel, feed rates of of =1.480mm/min were achieved, with overall cutting lengths of 166m. Tool TR-HO-3D ø 10,3 Work Material 50C DIN CK50 [ AII 1050] Drilling peed 100m/min (3.090 min -1 ) Drills TR-HO-3D Number of Holes , (holes) Continue (holes) Wear eed 1.480mm/min (0,48mm/rev) (holes) Abnormal wear Depth of Hole 32mm (Through) 397 (holes) Breakage Coolant Water oluble Changes in amount of hole oversize Machine Horizontal Machining Center Tool wear comparison TR-HO-3D Oversize (mm) 0,035 0,03 0,025 0,02 0,015 0,01 TR-HO-3D 15μm 6μm 0, Number of Holes Example of carbon steel processing. Because of the high feed rate of 0.48mm/rev, the competitor company's drill showed a large variation in hole expansion as well as low tool life. However, the Mega Muscle Drill was able to achieve 5200 holes (cutting length 166m) with stable hole sizes. The competitor A's hole expansion ranged up to 15um, while the Mega Muscle Drill had only a 6um variation. 7

8 Unmatched Processing Efficiency! Drilling feeds exceeding mm/min! In the processing of alloy steel, feed rates of =1.140mm/min were achieved, with overall cutting lengths of 110m Tool TR-HO-5D ø10,5 Work Material CM440 (Alloy teel) Drilling peed 80m/min (2.430min -1 ) eed 1.140mm/min (0,47mm/rev) Drills TR-HO-5D Number of Holes , (holes) Wear (holes) Wear Depth of Hole Coolant 50mm (Through) Water oluble (holes) (holes) Breakage Breakage Machine Horizontal Machining Center Tool wear comparison Changes in amount of hole oversize TR-HO-5D 0,05 25μm 0,04 Oversize (mm) 0,03 0,02 0,01 TR-HO-5D 11μm Number of Holes Example of hole processing in alloy steel. At high feed machining of 0.47mm/rev, 's drill was found to be unstable in hole size as well as having low tool life. However, the Mega Muscle Drill exceeded 2200 (cutting length 110m) holes of tool life, limited by normal wear, thus decreasing overall tooling and part cost per unit. When comparing the hole expansion values, was found to have a large variation of up to 25μm.While the Mega Muscle Drill had up to 11μm. eed rates of =1010mm/min were achieved in 30HRC alloy steel. Tool TR-HO-5D ø10,8 Work Material CM440 (30HRC) (Alloy teel) Drilling peed 70m/min (2.060min -1 ) eed 1.010mm/min (0,49mm/rev) Drills TR-HO-5D Number of Holes (holes) (holes) Wear Wear Depth of Hole Coolant 50mm (Through) Water oluble 174 (holes) 300 (holes) Breakage Abnormal wear Machine Horizontal Machining Center Example of hole processing in 30HRC alloy steel.at high feed drilling rates such as 0.49mm.rev, the 's product shows abnormal wear and premature breakage. After the drilling of 1700 holes, the wear of the Mega Muscle drill was stable, thus allowing for more regrinds and processing time per drill, reducing the overall process cost. Tool wear comparison TR-HO-5D 8

9 Recommended Drilling Conditions TR-HO-3D/5D Vc Ø Mild teels - Low Carbon teels Carbon teels Alloys teels C ~150HB 35C 50C ~210HB CM Cr NCM 16~28HRC ~500 N/mm 2 ~710 N/mm 2 710~900 N/mm 2 80 ~ 120 m/min 80 ~ 120 m/min 60 ~ 90 m/min ,18 ~ 0, ,18 ~ 0, ,18 ~ 0, ,21 ~ 0, ,21 ~ 0, ,21 ~ 0, ,25 ~ 0, ,25 ~ 0, ,25 ~ 0, ,28 ~ 0, ,28 ~ 0, ,28 ~ 0, ,32 ~ 0, ,32 ~ 0, ,32 ~ 0, ,35 ~ 0, ,35 ~ 0, ,35 ~ 0, ,39 ~ 0, ,39 ~ 0, ,39 ~ 0, ,42 ~ 0, ,42 ~ 0, ,42 ~ 0, ,46 ~ 0, ,46 ~ 0, ,46 ~ 0, ,49 ~ 0, ,49 ~ 0, ,49 ~ 0, ,48 ~ 0, ,48 ~ 0, ,48 ~ 0, ,54 ~ 0, ,54 ~ 0, ,54 ~ 0,72 TR-HO-3D/5D Vc Ø Alloys teels Cast Iron Ductile Cast Iron CM Cr NCM 28~35HRC 900~1100 N/mm 2 GG C250 ~350 N/mm 2 GGG CD450 CD ~600 N/mm 2 60 ~ 90 m/min 80 ~ 120 m/min 60 ~ 100 m/min ,18 ~ 0, ,18 ~ 0, ,18 ~ 0, ,21 ~ 0, ,21 ~ 0, ,21 ~ 0, ,25 ~ 0, ,25 ~ 0, ,25 ~ 0, ,28 ~ 0, ,28 ~ 0, ,28 ~ 0, ,32 ~ 0, ,32 ~ 0, ,32 ~ 0, ,35 ~ 0, ,35 ~ 0, ,35 ~ 0, ,39 ~ 0, ,39 ~ 0, ,39 ~ 0, ,42 ~ 0, ,42 ~ 0, ,42 ~ 0, ,46 ~ 0, ,46 ~ 0, ,46 ~ 0, ,49 ~ 0, ,49 ~ 0, ,49 ~ 0, ,48 ~ 0, ,56 ~ 0, ,48 ~ 0, ,54 ~ 0, ,63 ~ 0, ,54 ~ 0,81 1. The indicated speeds and feeds are for water soluble oil. 2. uitable cutting fluid is water-emulsifiable high density oil (less than 20 times dilution). 3. When using non-water soluble oil or water-emulsifiable (over 20times dilution), reduce drilling speed by 30%. 4. When inserting a drill into the machine, use a collet that does not have any scratches or dust located within internal bore. Also, reduce deflection of drill to less than 0.02mm. 5. asten the work material to reduce the possibility of work deformation, deflection of machined surface, or vibration. 6. A clogged oil hole can lead to a breakage. Make sure that a filter is attached to the oil feeder. 9

10 Recommended Drilling Conditions TR-HO-10D Vc Ø Mild teels Low Carbon teels C ~150 HB ~500 N/mm 2 Carbon teels Alloy teels Cast Iron Ductile Cast Iron 35C - 10C ~210 HB ~710 N/mm 2 CM - Cr - NCM 16 ~ 28 HRC 710 ~ 900 N/mm 2 80 ~ 120 m/min 80 ~ 120 m/min 60 ~ 120 m/min ,18 ~ 0, ,18 ~ 0, ,18 ~ 0, ,18 ~ 0, ,18 ~ 0, ,21 ~ 0, ,21 ~ 0, ,21 ~ 0, ,21 ~ 0, ,21 ~ 0, ,25 ~ 0, ,25 ~ 0, ,25 ~ 0, ,25 ~ 0, ,25 ~ 0, ,28 ~ 0, ,28 ~ 0, ,28 ~ 0, ,28 ~ 0, ,28 ~ 0, ,32 ~ 0, ,32 ~ 0, ,32 ~ 0, ,32 ~ 0, ,32 ~ 0, ,35 ~ 0, ,35 ~ 0, ,35 ~ 0, ,35 ~ 0, ,35 ~ 0, ,39 ~ 0, ,39 ~ 0, ,39 ~ 0, ,39 ~ 0, ,39 ~ 0, ,42 ~ 0, ,42 ~ 0, ,42 ~ 0, ,42 ~ 0, ,42 ~ 0,60 C N/mm 2 CD 450 CD ~ 600N/mm 2 1. The indicated speeds and feeds are for water soluble oil or MQL (approx.50ml/hour) 2. uitable cutting fluid is water-emulsifiable high density oil (less than 20 times dilution). 3. When using non-water soluble oil or water-emulsifiable (over 20times dilution), reduce drilling speed by 30%. 4. When inserting a drill into the machine, use a collet that does not have any scratches or dust located within internal bore. Also, reduce deflection of drill to less than 0.02mm. 5. asten the work material to reduce the possibility of work deformation, deflection of machined surface, or vibration. 6. A clogged oil hole can lead to a breakage. Make sure that a filter is attached to the oil feeder. 7. ake a pilot hole before using TR-HO-10D in accordance with recommended operation. 10

11 NOTE 11

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