TOOLS NEWS. Unique geometry minimizes chatter and vibration! Low cutting resistance, double sided insert face mill for general machining WSX445

Transcription

1 TOOLS NEWS Update Low cutting resistance, double sided insert face mill for general machining Unique geometry minimizes chatter and vibration! B220G Insert Expansion Double Geometry Patent : Registration No

2 Low cutting resistance, double sided insert face mill for general machining New face milling cutter with innovative double sided insert. Perfect balance between high effi ciency and ease of use. Cost Performance Double sided insert type Single sided insert type Low resistance Designed to control abnormal insert breakage and body damage The unique conical insert seat and Anti Fly mechanism (A.F.I) hold the insert securely. The outer edge of the insert is not in contact with the body, thereby preventing damage if sudden fracturing occurs. The thick insert negates the need for a shim. Through Coolant Holes Improves chip discharge and prevents chip welding. 1 Anti Fly Insert mechanism (A.F.I)

3 Unique insert minimizes chatter and vibration Z Insert Geometry provides low cutting resistance itsubishi aterials proprietary Double sided, Z Geometry insert features a sharp cutting edge with low cutting resistance by utilizing features of both conventional positive and negative rake inserts. Axial center line Double sided, Z Geometry Cutting edge 26 For a sharper cutting edge Double sided insert Conventional positive insert Axial center line Conventional negative insert Axial center line For a sharper cutting edge Single sided insert For higher edge strength Double sided insert Rake angle mounted an insert. 2

4 CUTTING RESISTANCE s low cutting resistance equals that of single sided insert cutters. The low axial and radial forces reduce vibrations to a minimum. Cutting resistance (N) [Comparison of the back force] Negative (Double sided) 40% Lower cutting resistance Positive (Single sided) breaker Conventional insert Principal Force Back Force <Cutting condition> Feed Force Work material : SC440 Cutter Dia. : 125 mm Cutting speed : 200 m/min <Back force> Feed per tooth : 0.2 mm/tooth Cutting force in the axial direction. Depth of cut : ap=4.0 mm ae=100 mm Back force can cause inaccuracy and vibration, resulting in deflection of the Cutting mode : Dry Single insert work piece as well as cutting tools. CHIP DISCHARGE EFFECT Chips are discharged outwardly because of the negative/positive edge design. This helps prevent jamming of continuous chips also damage to the coolant holes. Conventional positive insert Conventional negative insert A Conventional negative insert B <Cutting condition> Work material : SC440 Cutting speed : 150 m/min Feed per tooth : 0.2 mm/tooth Depth of cut : ap=4 mm ae=100 mm Cutting mode : Dry The chips generated are helical and are discharged outwardly. Chips can be discharged inwardly and can cause problems. ABRASIVE DAAGE FRO CHIPS Depth of cut can be set without regard to the unused corner. Conventional double sided insert Chips can contact the unused corner. The chips generated do not contact the unused corner. 3

5 BREAKER SYSTE Breaker series for varied cutting condition Focus on cutting edge sharpness Stable Cutting (Continuous cutting, Without scale, etc.) Unstable Cutting (Interrupted cutting, With scale, etc.) Focus on cutting edge strength Lbreaker breaker Rbreaker Hbreaker The high rake angle boosts cutting performance. Positive land retains strength and provides low cutting resistance. First recommendation for general applications. A good balance of edge strength and sharpness is provided by the optimized positive land and rake angle. For unstable applications. Enhanced edge strength and retention of sharpness is provided by the negative land and positive rake angle respectively. For demanding applications. A stronger land and reduced positive rake angle provides maximum edge strength. Work aterial Cutting Condition Light General Heavy P L R H R L K L R H R S L N L H H 4

6 Low cutting resistance, double sided insert face mill for general machining INSERT GRADE FOR A WIDE RANGE OF ATERIALS ISO Application range PVD ISO Application range PVD ISO Application range CVD PVD P Steel P10 P20 P30 P40 P6120 P P7130 K Cast Iron K10 K20 K30 K40 C5020 ISO Application range PVD ISO Application range ISO Application range PVD S Heat Resistant Alloy Ti Alloy S10 S20 S30 S40 P9120 N Non-Ferrous etal N10 N20 N30 N40 TF15 H Hardened aterials H10 H20 H30 H40 P6100, P7100, P With accumulated Al-Ti-Cr-N based PVD coating TOUGH Σ Technology A fusion of the separate coating technologies; PVD and multi-layering realises extra toughness. Base layer High Al-(Al, Ti)N The new technology Al-(Al, Ti)N coating provides stabilisation of the high hardness phase and succeeds in dramatically improving wear, crater and welding resistance. Best layer of each workpiece P (Al,Cr)N Tough! Thermal Cracks TiN Thermal Cracks ulti-layering of the coating prevents any cracks penetrating through to the substrate. Graphical representation. S Tough! Notching CrN Notching Graphical representation. Tough! Resistant Chipping Welding by Chipping CVD coating C5020 First recommendation for cast iron milling. C5020 has excellent wear resistance and also controls thermal cracking and chipping that are common when machining ductile cast iron. Comparison of Coating Surface Extermely smooth coating Black super-smooth coating An extremely smooth black super-smooth coating prevents abnormal damage such as weld chipping. Conventional coating Black super-smooth coating 5

7 FACE ILLING <GENERAL CUTTING> Finishing P K N S H Steel Cast Iron Non-ferrous etal Heat Resistant Alloy Hardened Steel Roughing Fig.1 ø40 ø50 ø63 ø80 LCCB BD DCON KWW L8 CBDP LF Fig.2 ø100 ø125 ø160 LCCB BD DCON KWW L8 CBDP LF a Unique design both sides insert a Sudden fracture & welding prevention function a Highly effi cient chip discharge DAH DCCB DC 45 DCX APX Fig.3 ø200 DAH DCCB 45 DC DCX BD ø101.6 DCON KWW ø18 APX L8 CBDP LF y ARBOR TYPE Type Coarse Pitch Fine Pitch Extra Fine Pitch Order Number KAPR :45 GAP :+17 GAF :-6 +1 T :-7-2 I : DCCB DC DCX Right hand tool holder only. Stock Coolant Number Dimensions (mm) R Hole of Teeth DC DCX LF DCON CBDP DAH DCCB LCCB BD KWW L8-040A03AR a u A03AR a u A04AR a u R08004CA a u R10005DA a u R12506EA a u R16007FA a u R20008KN a A04AR a u A04AR a u A05AR a u R08006CA a u R10007DA a u R12508EA a u R16010FA a u R20012KN a A05AR a u A06AR a u R08008CA a u R10010DA a u R12512EA a u R16016FA a u R20020KN a (Note1) A set bolt to the arbor is not supplied with the body. Please refer to page 8, when ordering. (Note2) Please use a set bolt of the FC(metric) type on the cutter body from 40 to 63 in diameter(dc). (Note3) Please use a set bolt of the FA type on the cutter body from 80 to 200 in diameter(dc). WT : Tool Weight SPARE PARTS Tool Holder Number TPS4R TIP15W Clamp Torque (N m) : TPS4R=3.5 Clamp Screw Wrench (Insert) 45 APX WT APX Type (kg) (mm) (Fig.) a : Inventory maintained in Japan. 6

8 Low cutting resistance, double sided insert face mill for general machining For metric arbors The cutter bore diameter DCON is indicated in millimetres. Fig.1 ø40 ø50 ø63 ø80 ø160 LCCB Fig.3 BD DCON KWW DAH DCCB DC 45 DCX BD DCON KWW L8 ø100 ø125 BD DCON KWW DAH DCCB DC DCX 45 Fig.4 BD ø101.6 ø14 ø200 ø18 16 DCON KWW CBDP LF CBDP LF L8 APX L8 CBDP LF APX CBDP LF Fig.2 LCCB L8 y ARBOR TYPE Type Coarse Pitch Fine Pitch Extra Fine Pitch KAPR :45 GAP :+17 GAF :-6 +1 T :-7-2 I : Order Number Stock Coolant Number Dimensions (mm) WT APX Type R Hole of Teeth DC DCX LF DCON CBDP DAH DCCB LCCB BD KWW L8 (kg) (mm) (Fig.) -040A03AR a u A03AR a u A04AR a u A04AR a u B05AR a u B06AR a u C07NR a C08NR a A04AR a u A04AR a u A05AR a u A06AR a u B07AR a u B08AR a u C10NR a C12NR a A05AR a u A06AR a u A08AR a u B10AR a u B12AR a u C16NR a C20NR a DCCB DC DCX (Note1) A set bolt to the arbor is not supplied with the body. Please refer to page 8, when ordering. (Note2) Please use a set bolt of the FC(metric) type on the cutter body from 40 to 63 in diameter(dc). (Note3) Please use a set bolt of the FA type on the cutter body from 80 to 200 in diameter(dc). WT : Tool Weight 45 DCCB DC DCX Right hand tool holder only. APX 45 APX 7 a : Inventory maintained in Japan.

9 DCX DC 45 DCON APX LH LF y SHANK TYPE Type Coarse Pitch Fine Pitch Order Number Stock Coolant Number Dimensions (mm) R Hole of Teeth DC DCX LF DCON LH R4003SA32 a u R5003SA32 a u R6304SA32 a u R8004SA32 a u R4004SA32 a u R5004SA32 a u R6305SA32 a u R8006SA32 a u WT : Tool Weight SPARE PARTS Tool Holder Number TPS4R TIP15W Clamp Torque (N m) : TPS4R=3.5 SET BOLT (SOLD SEPARATELY) Clamp Screw Wrench (Insert) Right hand tool holder only. WT (kg) APX (mm) Set Bolt Arbor Type With coolant hole Without coolant hole Type Reference Dimensions (mm) Geometry a b c d e f g -040AooAR HSC08025H HSC AooAR HSC10030H HSC AooAR HSC10030H HSC AooAR Order Number HSC12035H Order Number HSC12035 HSC BooAR BA16033H BooAR BA20040H CooNR No coolant hole CooNR No coolant hole Fig.1 e Fig.2 a d f c b R080ooCA HSC12035H HSC12035 HSC a b g R100ooDA BA16033H R125ooEA BA20040H R160ooFA BA24045H R200ooKN No coolant hole e d c (Note 1) Internal coolant is necessary with the set bolt. 8

10 Low cutting resistance, double sided insert face mill for general machining INSERTS WITH BREAKER Work aterial P K N S H Steel Cast Iron Non-ferrous etal Heat-resistant Alloy, Titanium Alloy Hardened Steel Cutting Conditions : : Stable Cutting : General Cutting : Unstable Cutting Honing : E : Round F : Sharp Coated Carbide Dimensions (mm) Shape Order Number Class Honing C5020 P6120 P6130 P7130 P9120 TF15 IC S BS RE Geometry SNGU140812ANFR-L G F a SNGU140812ANER-L G E a a a a a a RE SNGU140812ANER- G E a a a a a a IC SNU140812ANER- E a a a a a a a SNU140812ANER-R E a a a a a SNU140812ANER-H E a a a a a BS 6.3 S WIPER INSERTS = Coated Dimensions (mm) Shape Order Number Class Honing C5020 P6120 L W1 S BS RE Geometry WNGU1406ANEN8C- G E a a a W1 BS RE L S yinstructions for use of wiper inserts = Fig.1 Fig.2 a Wiper inserts for are two-cornered. Please set as shown in Fig.1. a Excellent finished surfaces can be achieved with one wiper. Set more than 2 wiper inserts, equally spaced, when the feed per revolution is larger than 8mm/rev. 9 a : Inventory maintained in Japan. (10 inserts in one case)

11 RECOENDED CUTTING CONDITIONS y Dry cutting P Work aterial Hardness Grade ild Steel <180HB P6120 P6130 vc (m/min) Finish Light Cutting Light Rough Cutting edium Heavy Cutting fz (mm/tooth) ap(mm) fz (mm/tooth) ap(mm) fz (mm/tooth) ap(mm) 250 ( ) 0.15 ( ) < ( ) < ( ) < ( ) 0.15 ( ) < ( ) < ( ) <5.0 Carbon Steel Alloy Steel HB P6120 P ( ) 0.15 ( ) < ( ) < ( ) < ( ) 0.15 ( ) < ( ) < ( ) <5.0 Alloy Steel Pre-Hardened Steel 35 45HRC P6120 P ( ) 0.15 ( ) < ( ) < ( ) < (90 150) 0.15 ( ) < ( ) < ( ) <5.0 Austenitic Ferritic and artensitic P ( ) 0.15 ( ) < ( ) <3.0 K Austenitic P ( ) 0.15 ( ) 0.2 ( ) >200HB <2.0 <3.0 Two-phase Hardened Gray Cast Iron P7130 <280Pa 160 ( ) 0.15 ( ) < ( ) <3.0 P7130 <450HB 150 ( ) 0.15 ( ) < ( ) <3.0 Tensile Strength <350Pa C ( ) 0.15 ( ) < ( ) < ( ) < ( ) 0.15 ( ) < ( ) < ( ) <5.0 Ductile Cast Iron Tensile Strength <800Pa C ( ) 0.15 ( ) < ( ) < ( ) < ( ) 0.15 ( ) < ( ) < ( ) <5.0 H Hardened Steel 40 55HRC 50 (30 70) 0.05 ( ) < ( ) <2.0 Refer to the table above and set the cutting conditions to match the application. Wet cutting is recommended, when focusing on the surface fi nish. (Life is lower than dry cutting.) 10

12 Low cutting resistance, double sided insert face mill for general machining y Wet cutting P Work aterial Hardness Grade vc (m/min) Finish Light Cutting Light Rough Cutting edium Heavy Cutting fz (mm/tooth) ap(mm) fz (mm/tooth) ap(mm) fz (mm/tooth) ap(mm) P6120 ild Steel <180HB 150 ( ) 0.15 ( ) < ( ) < ( ) <5.0 P6130 Carbon Steel Alloy Steel Alloy Steel Pre-Hardened Steel P HB 120 (80 160) 0.15 ( ) < ( ) < ( ) <5.0 P6130 P HRC 100 (80 120) 0.15 ( ) < ( ) < ( ) <5.0 P6130 Austenitic Ferritic and artensitic P (80 180) 0.15 ( ) < ( ) <3.0 K Austenitic P (80 150) 0.15 ( ) 0.2 ( ) >200HB <2.0 <3.0 Two-phase Hardened Gray Cast Iron P7130 <280Pa 100 (80 150) 0.15 ( ) < ( ) <3.0 P7130 <450HB 90 (50 140) 0.15 ( ) < ( ) <3.0 <350Pa C ( ) 0.15 ( ) < ( ) < ( ) < ( ) 0.15 ( ) < ( ) < ( ) <5.0 Ductile Cast Iron <800Pa C ( ) 0.15 ( ) < ( ) < ( ) < (80 140) 0.15 ( ) < ( ) < ( ) <5.0 N Aluminum Alloy TF ( ) 0.2 ( ) <5.0 S H P9120 Titanium Alloy 50 (40 60) 0.05 ( ) < ( ) <2.0 P9120 Heat Resistant Alloy 40 (20 50) 0.05 ( ) < ( ) <2.0 Hardened Steel 40 55HRC 50 (30 70) 0.05 ( ) < ( ) <2.0 Refer to the table above and set the cutting conditions to match the application. Wet cutting is recommended, when focusing on the surface fi nish. (Life is lower than dry cutting.) 11

13 Cutting performance Comparison in finished surface of aluminum (A6061) Feature of breaker for aluminum Rake face polished Improved welding resistance Sharp edge Focus the sharpness a Breaker for aluminum have sharp cutting edges. Handling them with bare hands may cause injuries. (μm) Roughness profi le Axial magnifi cation:x2,000 Transverse magnifi cation:x50) Surface roughness Surface quality L breaker TF15 Ra 0.123μm Rz 0.842μm (μm) Roughness profi le Axial magnifi cation:x2,000 Transverse magnifi cation:x50) Conventional A Ra 0.110μm Rz 0.934μm Cloudiness Conventional B (μm) Roughness profi le Axial magnifi cation:x2,000 Transverse magnifi cation:x50) Ra 0.770μm Rz 3.062μm Rough <Cutting conditions> Cutter Dia. : 125ø 4 inserts Center cut Cutting speed : 500 m/min Feed per tooth : 0.1 mm/tooth Depth of cut : ap=2.0 mm ae=100 mm Cutting mode : Dry Tool life comparison in FCD Flank wear VB (mm) Conventional A Conventional B Breaker C5020 breaker C Conventional A Cutting length (m) <Cutting conditions> Cutter Dia. : 125ø 1 insert Center cut Cutting speed : 200 m/min Feed per tooth : 0.2 mm/tooth Depth of cut Cutting mode : ap=3.0 mm ae=100 mm : Dry Conventional B 12

14 Low cutting resistance, double sided insert face mill for general machining APPLICATION EXAPLES Cutter Body Insert (Grade) -050A04AR SNU140812ANER-R(P6120) S45C Workpiece Cutting Conditions Component Cutting Speed (m/min) Feed per Tooth (mm/tooth) Depth of Cut (mm) Cutting mode Round bar ap=2 ae=25 Dry Double sided insert became possible in BT30 arbor that was not able to support conventional. achieved the equivalent of tool life to, the number of corner from that has doubled, were able to reduce the cost down. Results Cutter Body Insert (Grade) R12508EA SNGU140812ANER- (P6120) STK12 Workpiece Cutting Conditions Component Cutting Speed (m/min) Feed per Tooth (mm/tooth) Depth of Cut (mm) Cutting mode Thin plate ap= ae=120 Dry Spindle load could be suppressed to 80% of conventional products, thus has offered better chip discharge performance and made smooth and silent machining. Results 13

15 Cutter Body Insert (Grade) -080A08AR SNGU140812ANER- (P6120) FCD700 Workpiece Cutting Conditions Component Cutting Speed (m/min) Feed per Tooth (mm/tooth) Depth of Cut (mm) Cutting mode Results Conventional Automotive component ap=2.0 ae=60 Dry Number of machined parts (pcs. /corner) achieved double tool life compared to conventional products without insert fracturing in interrupted machining. Cutter Body Insert (Grade) 15-5PH Hardened R10007DA SNGU140812ANER-L (P9120) Workpiece Cutting Conditions Component Cutting Speed (m/min) Feed per Tooth (mm/tooth) Depth of Cut (mm) Cutting mode Results Aerospace component ap= ae=80 Wet Number of machined parts(pass) 6 8 Conventional Number of work pieces increased by 1.5 times or more since prevents thermal crack. 14

16 Low cutting resistance, double sided insert face mill for general machining 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. ITSUBISHI ATERIALS 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 URL : (Tools specifications subject to change without notice.) EXP-14-E E( - )