Jongen UNI-MILL VHC milling cutter

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1 Jongen Werkzeugtechnik Jongen UNI-MILL VHC milling cutter Trochoidal milling at the highest level

Jongen UNI-MILL VHC milling cutter Static and dynamic "trochoidal milling" is a combination of circular and linear slot milling, which provides a highly increased chip removal rate as well as growth

Due to trochoidal milling, roughing with deep depths of cut is possible. The shortest possible processing times can be realised by supporting a corresponding CAM software.

Due to special trochoidal machining path (in spiral from), a significantly greater cutting diameter with the application of smaller tool diameter can be applied when compared to conventional slot

2 Jongen UNI-MILL VHC milling cutter Static and dynamic "trochoidal milling" is a combination of circular and linear slot milling, which provides a highly increased chip removal rate as well as growth in productivity by shortening the processing times. This modern strategy enables machining at increased feed speeds with large cross sections and high axial depths of cut. Due to trochoidal milling, roughing with deep depths of cut is possible. The shortest possible processing times can be realised by supporting a corresponding CAM software. A combination of circular milling (left) with slot milling (middle) creates trochoidal milling (right). Due to special trochoidal machining path (in spiral from), a significantly greater cutting diameter with the application of smaller tool diameter can be applied when compared to conventional slot milling. As the milling cutter only partially fills the slot, chips are transported rapidly and completely out of the machined area and with them the heat from machining. Furthermore, the cutting edge length can be applied fully and more effectively with these tools. The lower cutting pressures are evenly spread along the entire cutting edge and despite the extreme cutting parameters the wearing process is, therefore, less than in conventional milling. The tools have longer tool life under this milling process. Thus, in total less tools are required. Due to the increased number of teeth with 5 teeth, the feed speed can be increased and, therefore, the processing time can be reduced. The new VHC- tools of Jongen enable the process reliability at high cutting depths, cutting speeds and feeds, and can be simultaneously applied with low cutting forces even under critical machining conditions. Within the new VHC-Program, optimally adapted tools are available for different materials in respect to substrate, coating and geometry. The Jongen UNI-MILL VHC-tools set new standards in trochoidal milling. 2

3 Jongen UNI-MILL VHC milling cutter Characteristics VHC 516W VHC 526W VHC 555W VHC 567W Geometry Designed especially for trochoidal milling strategies Application area: steel Application area: stainless steel & high grade steel Application area: cast iron Application area: hard-to-machine & heat resistant materials Application area: hard machining Optimized chip spaces stable tool core generously carried out chip spaces Holding fixture made to DIN 6535-HB stable tool holder Increasing neck length increment of utility length up to DIN-clamping length Differential tooth pitch Optimized macro geometry high cutting volume Chip breaker Optimized micro geometry highest tool live Quality Ti10 Ti08 Ti08 HX70 Finest grain carbide, ISO-field K05-K10 for highest wearing quality Coating low friction coefficient prevention of adhesion and build-up material on cutting edge optimal chip flow high cutting parameters high protection against wearing process Regrinding capability of the tool High cost-benefit-factor 3

4 4 Overview of the program

5 Overview of the program VHC 516W Ti10 HRC 52 Page 6 VHC 526W Ti08 HRC 48 Page 8 VHC 555W Ti08 Page 10 VHC 567W HX70 HRC 70 Page 12 Key to symbols Roughing Pre-Finishing Finishing Steel Cast iron GG(G) Highly heat-resistant materials Hard machining 5

6 VHC 516W Ti10 VHC 516W Ti10 - Technical Data HRC 52 Tolerance D ø6,0-20,0= -0,02-0,04 ~45 DIN 6535-HB Order-No. D s l N d 1 d L Z VHC 516W-06 Ti10 6 0,15x , VHC 516W-08 Ti10 8 0,15x , VHC 516W-10 Ti ,20x , VHC 516W-12 Ti ,20x , VHC 516W-16 Ti ,30x , VHC 516W-20 Ti ,40x , Key to symbols Roughing Pre-Finishing Finishing Steel Cast iron GG(G) Edge Chamfer Chip breaker Defined cutting edge preparation ~45 Average spiral angle Uneven cutting pitch Profile slot 6 DIN 6535-HB Shank shape made to DIN 6535-HB (Weldon) Submersible milling tool

7 VHC 516W Ti10 VHC 516W Ti10 - Cutting Data Recommendation Material Structural steel Unalloyed steel <800 N/mm² D Z Vc [m/min] fz fz hm max. ap max ae ae max n [min-1] Vf [mm/min] Q [cm 3 /min] φs [ ] φs [ ] ( ) 0,06 (0,04-0,08) 0, ,6 1, ,2 36,9 (10,0-53,1) ( ) 0,07 (0,05-0,09) 0, ,8 1, ,6 36,9 (10,0-53,1) ( ) 0,08 (0,06-0,10) 0, ,0 2, ,7 36,9 (10,0-53,1) ( ) 0,09 (0,07-0,11) 0, ,2 2, ,4 36,9 (10,0-53,1) ( ) 0,11 (0,09-0,13) 0, ,6 3, ,1 36,9 (10,0-53,1) ( ) 0,14 (0,12-0,16) 0, ,0 4, ,0 36,9 (10,0-53,1) ( ) 0,06 (0,04-0,08) 0, ,6 1, ,5 36,9 (10,0-53,1) Tool steel Heat-treatable steel Alloyed steel N/mm² ( ) 0,07 (0,05-0,09) 0, ,8 1, ,5 36,9 (10,0-53,1) ( ) 0,08 (0,06-0,10) 0, ,0 2, ,9 36,9 (10,0-53,1) ( ) 0,09 (0,07-0,11) 0, ,2 2, ,6 36,9 (10,0-53,1) ( ) 0,11 (0,09-0,13) 0, ,6 3, ,5 36,9 (10,0-53,1) ( ) 0,14 (0,12-0,16) 0, ,0 4, ,2 36,9 (10,0-53,1) ( ) 0,06 (0,04-0,08) 0, ,6 1, ,5 36,9 (10,0-53,1) High alloyed steel ( ) 0,07 (0,05-0,09) 0, ,8 1, ,8 36,9 (10,0-53,1) ( ) 0,08 (0,06-0,10) 0, ,0 2, ,1 36,9 (10,0-53,1) ( ) 0,09 (0,07-0,11) 0, ,2 2, ,5 36,9 (10,0-53,1) ( ) 0,11 (0,09-0,13) 0, ,6 3, ,4 36,9 (10,0-53,1) ( ) 0,14 (0,12-0,16) 0, ,0 4, ,2 36,9 (10,0-53,1) (20-60) 0,06 (0,04-0,08) 0, ,6 1, ,1 36,9 (10,0-53,1) (20-60) 0,07 (0,05-0,09) 0, ,8 1, ,0 36,9 (10,0-53,1) Hardox ( ) (20-60) 0,08 (0,06-0,10) 0, ,0 2, ,4 36,9 (10,0-53,1) (20-60) 0,09 (0,07-0,11) 0, ,2 2, ,6 36,9 (10,0-53,1) (20-60) 0,11 (0,09-0,13) 0, ,6 3, ,3 36,9 (10,0-53,1) (20-60) 0,14 (0,12-0,16) 0, ,0 4, ,2 36,9 (10,0-53,1) (30-60) 0,06 (0,04-0,08) 0, ,6 1, ,9 36,9 (10,0-53,1) (30-60) 0,07 (0,05-0,09) 0, ,8 1, ,7 36,9 (10,0-53,1) Toolox (33+44) (30-60) 0,08 (0,06-0,10) 0, ,0 2, ,3 36,9 (10,0-53,1) (30-60) 0,09 (0,07-0,11) 0, ,2 2, ,5 36,9 (10,0-53,1) (30-60) 0,11 (0,09-0,13) 0, ,6 3, ,8 36,9 (10,0-53,1) (30-60) 0,14 (0,12-0,16) 0, ,0 4, ,0 36,9 (10,0-53,1) ( ) 0,06 (0,04-0,08) 0, ,6 1, ,5 36,9 (10,0-53,1) ( ) 0,07 (0,05-0,09) 0, ,8 1, ,5 36,9 (10,0-53,1) Cast iron GGG ( ) 0,08 (0,06-0,10) 0, ,0 2, ,9 36,9 (10,0-53,1) ( ) 0,09 (0,07-0,11) 0, ,2 2, ,6 36,9 (10,0-53,1) hm = Chip thickness φs = Pressure angle ( ) 0,11 (0,09-0,13) 0, ,6 3, ,5 36,9 (10,0-53,1) ( ) 0,14 (0,12-0,16) 0, ,0 4, ,2 36,9 (10,0-53,1) 7

8 VHC 526W Ti08 VHC 526W Ti08 - Technical Data HRC 48 Tolerance D ø6,0-20,0= -0,02-0,04 ~45 DIN 6535-HB Order-No. D s l N d 1 d L Z VHC 526W-06 Ti08 6 0,15x , VHC 526W-08 Ti08 8 0,15x , VHC 526W-10 Ti ,20x , VHC 526W-12 Ti ,20x , VHC 526W-16 Ti ,30x , VHC 526W-20 Ti ,40x , Key to symbols Roughing Pre-Finishing Finishing Steel Edge Chamfer Chip breaker Defined cutting edge preparation ~45 Average spiral angle Uneven cutting pitch Profile slot DIN 6535-HB Shank shape made to DIN 6535-HB (Weldon) Submersible milling tool 8

9 VHC 526W Ti08 VHC 526W Ti08 - Cutting Data Recommendation Material D Z Vc [m/min] fz fz hm max. ap max ae ae max n [min-1] Vf [mm/min] Q [cm 3 /min] φs [ ] φs [ ] ( ) 0,09 (0,07-0,11) 0, ,6 1, ,9 36,9 (10,0-53,1) High alloyed steel <850 N/mm² ( ) 0,10 (0,08-0,12) 0, ,8 1, ,7 36,9 (10,0-53,1) ( ) 0,14 (0,12-0,16) 0, ,0 2, ,5 36,9 (10,0-53,1) ( ) 0,16 (0,14-0,18) 0, ,2 2, ,1 36,9 (10,0-53,1) ( ) 0,17 (0,15-0,19) 0, ,6 3, ,4 36,9 (10,0-53,1) ( ) 0,24 (0,22-0,26) 0, ,0 4, ,2 36,9 (10,0-53,1) ( ) 0,09 (0,07-0,11) 0, ,6 1, ,8 36,9 (10,0-53,1) High alloyed steel >850 N/mm² ( ) 0,09 (0,07-0,11) 0, ,8 1, ,4 36,9 (10,0-53,1) ( ) 0,11 (0,09-0,13) 0, ,0 2, ,3 36,9 (10,0-53,1) ( ) 0,13 (0,11-0,15) 0, ,2 2, ,6 36,9 (10,0-53,1) ( ) 0,15 (0,13-0,17) 0, ,6 3, ,7 36,9 (10,0-53,1) ( ) 0,20 (0,18-0,22) 0, ,0 4, ,2 36,9 (10,0-53,1) ( ) 0,04 (0,02-0,06) 0, ,6 1, ,1 36,9 (10,0-53,1) Structural steel Unalloyed steel <800 N/mm² ( ) 0,05 (0,03-0,07) 0, ,8 1, ,9 36,9 (10,0-53,1) ( ) 0,06 (0,04-0,08) 0, ,0 2, ,2 36,9 (10,0-53,1) ( ) 0,07 (0,05-0,09) 0, ,2 2, ,4 36,9 (10,0-53,1) ( ) 0,09 (0,07-0,11) 0, ,6 3, ,4 36,9 (10,0-53,1) ( ) 0,12 (0,10-0,14) 0, ,0 4, ,8 36,9 (10,0-53,1) ( ) 0,04 (0,02-0,06) 0, ,6 1, ,4 36,9 (10,0-53,1) Tool steel Heat-treatable steel Alloyed steel N/mm² ( ) 0,05 (0,03-0,07) 0, ,8 1, ,0 36,9 (10,0-53,1) ( ) 0,06 (0,04-0,08) 0, ,0 2, ,9 36,9 (10,0-53,1) ( ) 0,07 (0,05-0,09) 0, ,2 2, ,2 36,9 (10,0-53,1) ( ) 0,09 (0,07-0,11) 0, ,6 3, ,2 36,9 (10,0-53,1) ( ) 0,12 (0,10-0,14) 0, ,0 4, ,4 36,9 (10,0-53,1) hm = Chip thickness φs = Pressure angle 9

10 VHC 555W Ti08 VHC 555W Ti08 - Technical Data Tolerance D ø3,0-20,0= -0,02-0,04 38 DIN 6535-HB Order-No. D R l N d 1 d L Z VHC 555W-03 R01 Ti08 3 0, , VHC 555W-04 R01 Ti08 4 0, , VHC 555W-05 R01 Ti08 5 0, , VHC 555W-06 R01 Ti08 6 0, , VHC 555W-08 R02 Ti08 8 0, , VHC 555W-10 R02 Ti , , VHC 555W-12 R03 Ti , , VHC 555W-16 R03 Ti , , VHC 555W-20 R03 Ti , , Key to symbols Roughing Pre-Finishing Finishing Highly heat-resistant materials Radius Chip breaker Defined cutting edge preparation 38 Spiral angle Uneven cutting pitch DIN 6535-HB Shank shape made to DIN 6535-HB (Weldon) 10 Submersible milling tool

11 VHC 555W Ti08 VHC 555W Ti08 - Cutting Data Recommendation Material D Z Vc [m/min] fz fz hm max. ap max ae ae max n [min-1] Vf [mm/min] Q [cm 3 /min] φs [ ] φs [ ] (50-100) 0,11 (0,09-0,13) 0, ,18 0, ,4 28,4 (10,0-40,5) (50-100) 0,12 (0,10-0,14) 0, ,24 0, ,5 28,4 (10,0-40,5) (50-100) 0,12 (0,10-0,14) 0, ,30 0, ,2 28,4 (10,0-40,5) Titanium alloys >300 HB (e.g. TiALV6) (50-100) 0,15 (0,13-0,17) 0, ,36 0, ,8 28,4 (10,0-40,5) (50-100) 0,15 (0,13-0,17) 0, ,48 0, ,1 28,4 (10,0-40,5) (50-100) 0,23 (0,21-0,25) 0, ,60 1, ,5 28,4 (10,0-40,5) (50-100) 0,23 (0,21-0,25) 0, ,72 1, ,4 28,4 (10,0-40,5) (50-100) 0,29 (0,27-0,31) 0, ,96 1, ,3 28,4 (10,0-40,5) (50-100) 0,37 (0,35-0,39) 0, ,20 2, ,2 28,4 (10,0-40,5) (10-60) 0,14 (0,12-0,16) 0, ,12 0, ,7 23,1 (10,0-40,5) (10-60) 0,15 (0,13-0,17) 0, ,16 0, ,9 23,1 (10,0-40,5) (10-60) 0,15 (0,13-0,17) 0, ,20 0, ,4 23,1 (10,0-40,5) Nickel-base alloy hardenable (e.g. Inconell 718) (10-60) 0,18 (0,16-0,20) 0, ,24 0, ,9 23,1 (10,0-40,5) (10-60) 0,18 (0,16-0,20) 0, ,32 0, ,2 23,1 (10,0-40,5) (10-60) 0,29 (0,27-0,31) 0, ,40 0, ,4 23,1 (10,0-40,5) (10-60) 0,29 (0,27-0,31) 0, ,48 0, ,3 23,1 (10,0-40,5) (10-60) 0,36 (0,34-0,38) 0, ,64 1, ,4 23,1 (10,0-40,5) (10-60) 0,45 (0,43-0,47) 0, ,80 1, ,5 23,1 (10,0-40,5) ( ) 0,07 (0,05-0,09) 0, ,30 0, ,8 28,4 (10,0-53,0) ( ) 0,08 (0,06-0,10) 0, ,40 0, ,0 28,4 (10,0-53,0) ( ) 0,09 (0,07-0,11) 0, ,50 1, ,6 28,4 (10,0-53,0) High alloyed steel < 850 N/mm² ( ) 0,09 (0,07-0,11) 0, ,60 1, ,4 28,4 (10,0-53,0) ( ) 0,10 (0,08-0,12) 0, ,80 1, ,4 28,4 (10,0-53,0) ( ) 0,14 (0,12-0,16) 0, ,00 2, ,4 28,4 (10,0-53,0) ( ) 0,16 (0,14-0,18) 0, ,20 2, ,9 28,4 (10,0-53,0) ( ) 0,17 (0,15-0,19) 0, ,60 3, ,1 28,4 (10,0-53,0) ( ) 0,24 (0,22-0,26) 0, ,00 4, ,9 28,4 (10,0-53,0) ( ) 0,06 (0,04-0,08) 0, ,30 0, ,0 28,4 (10,0-53,0) ( ) 0,07 (0,05-0,09) 0, ,40 0, ,1 28,4 (10,0-53,0) ( ) 0,08 (0,06-0,10) 0, ,50 1, ,6 28,4 (10,0-53,0) High alloyed steel >850 N/mm² ( ) 0,08 (0,06-0,10) 0, ,60 1, ,3 28,4 (10,0-53,0) ( ) 0,09 (0,07-0,11) 0, ,80 1, ,1 28,4 (10,0-53,0) ( ) 0,11 (0,09-0,13) 0, ,00 2, ,9 28,4 (10,0-53,0) hm = Chip thickness φs = Pressure angle ( ) 0,13 (0,11-0,15) 0, ,20 2, ,8 28,4 (10,0-53,0) ( ) 0,15 (0,13-0,17) 0, ,60 3, ,0 28,4 (10,0-53,0) ( ) 0,20 (0,18-0,22) 0, ,00 4, ,4 28,4 (10,0-53,0) 11

12 VHC 567W HX70 VHC 567W HX70 - Technical Data HRC 70 Tolerance D ø4,0-20,0= -0,02-0,04 45 DIN 6535-HB Order-No. D R l N d 1 d L Z VHC 567W-04 R01 HX70 4 0, , VHC 567W-05 R01 HX70 5 0, , VHC 567W-06 R01 HX70 6 0, , VHC 567W-08 R02 HX70 8 0, , VHC 567W-10 R02 HX , , VHC 567W-12 R03 HX , , VHC 567W-16 R03 HX , , VHC 567W-20 R04 HX , , Key to symbols Roughing Pre-Finishing Finishing Cast iron Tempered steel Radius Defined cutting edge preparation 45 Spiral angle Profile slot DIN 6535-HB Shank shape made to DIN 6535-HB (Weldon) Submersible milling tool 12

13 VHC 567W HX70 VHC 567W HX70 - Cutting Data Recommendation Material D Z Vc [m/min] fz fz hm max. ap max ae ae max n [min-1] Vf [mm/min] Q [cm 3 /min] φs [ ] φs [ ] ( ) 0,030 (0,01-0,05) 0, ,32 0, ,3 32,9 (10,0-47,2) ( ) 0,030 (0,01-0,05) 0, ,40 0, ,5 32,9 (10,0-47,2) Tool steel Heat-treatable steel N/mm² HRC ( ) 0,050 (0,03-0,07) 0, ,48 0, ,4 32,9 (10,0-47,2) ( ) 0,060 (0,04-0,08) 0, ,64 1, ,0 32,9 (10,0-47,2) ( ) 0,080 (0,06-0,10) 0, ,80 1, ,7 32,9 (10,0-47,2) ( ) 0,100 (0,08-0,12) 0, ,96 1, ,5 32,9 (10,0-47,2) ( ) 0,110 (0,09-0,13) 0, ,28 2, ,5 32,9 (10,0-47,2) ( ) 0,130 (0,11-0,15) 0, ,60 3, ,6 32,9 (10,0-47,2) ( ) 0,030 (0,01-0,05) 0, ,24 0, ,9 28,4 (10,0-40,5) ( ) 0,040 (0,02-0,06) 0, ,30 0, ,9 28,4 (10,0-40,5) Tool steel Heat-treatable steel HRC ( ) 0,060 (0,04-0,08) 0, ,36 0, ,8 28,4 (10,0-40,5) ( ) 0,070 (0,05-0,09) 0, ,48 0, ,7 28,4 (10,0-40,5) ( ) 0,100 (0,08-0,12) 0, ,60 1, ,5 28,4 (10,0-40,5) ( ) 0,110 (0,09-0,13) 0, ,72 1, ,5 28,4 (10,0-40,5) ( ) 0,120 (0,10-0,14) 0, ,96 1, ,3 28,4 (10,0-40,5) ( ) 0,150 (0,13-0,17) 0, ,20 2, ,9 28,4 (10,0-40,5) (80-130) 0,030 (0,01-0,05) 0, ,20 0, ,4 25,9 (10,0-42,3) (80-130) 0,040 (0,02-0,06) 0, ,25 0, ,9 25,9 (10,0-42,3) Tool steel Heat-treatable steel HRC (80-130) 0,070 (0,05-0,09) 0, ,30 0, ,1 25,9 (10,0-42,3) (80-130) 0,080 (0,06-0,10) 0, ,40 0, ,6 25,9 (10,0-42,3) (80-130) 0,110 (0,09-0,13) 0, ,50 1, ,8 25,9 (10,0-42,3) (80-130) 0,120 (0,10-0,14) 0, ,60 1, ,6 25,9 (10,0-42,3) (80-130) 0,130 (0,11-0,15) 0, ,80 1, ,4 25,9 (10,0-42,3) (80-130) 0,160 (0,14-0,18) 0, ,00 2, ,0 25,9 (10,0-42,3) ( ) 0,04 (0,02-0,06) 0, ,32 0, ,5 36,9 (10,0-53,1) ( ) 0,04 (0,02-0,06) 0, ,40 0, ,8 36,9 (10,0-53,1) ( ) 0,06 (0,04-0,08) 0, ,60 1, ,1 36,9 (10,0-53,1) Cast Iron GG(G) ( ) 0,07 (0,05-0,09) 0, ,80 1, ,1 36,9 (10,0-53,1) ( ) 0,08 (0,06-0,10) 0, ,00 2, ,8 36,9 (10,0-53,1) hm = Chip thickness φs = Pressure angle ( ) 0,09 (0,07-0,11) 0, ,20 2, ,2 36,9 (10,0-53,1) ( ) 0,11 (0,09-0,13) 0, ,60 3, ,1 36,9 (10,0-53,1) ( ) 0,14 (0,12-0,16) 0, ,00 4, ,4 36,9 (10,0-53,1) 13

Jongen UNI-MILL VHC milling cutter Principles and strategies of trochoidal milling Conventional milling Example: full slot milling Pressure angle 180 STATIC trochoidal milling describes the

hm = not constant chip thickness V f = constant f z = constant feed speed per tooth a p = 1-2xD a e = 1xD n = normal hm = not constant chip thickness V f = constant f z = constant feed speed

14 Jongen UNI-MILL VHC milling cutter Principles and strategies of trochoidal milling Conventional milling Example: full slot milling Pressure angle 180 STATIC trochoidal milling describes the optimised control of cycles Applying intelligent milling paths, it could be machined with constant V f up to a e max. hm = not constant chip thickness V f = constant f z = constant feed speed per tooth a p = 1-2xD a e = 1xD n = normal hm = not constant chip thickness V f = constant f z = constant feed speed per tooth a p = cutting edge length can be fully applied a e = variable n = high Advantages over conventional strategy: - higher chip volume - longer tool life - application of whole cutting edge length Not constant chip thickness (hm) indicates to unequal pressure! 14

Jongen UNI-MILL VHC milling cutter DYNAMIC trochoidal milling Depending on material type, a maximum pressure angle and a corresponding average chip thickness can be defined Average chip thickness hm

15 Jongen UNI-MILL VHC milling cutter DYNAMIC trochoidal milling Depending on material type, a maximum pressure angle and a corresponding average chip thickness can be defined Average chip thickness hm = f z a e x D f z = Feed speed per tooth a e = Radial depth of cut D = Diameter of the tool in use hm = constant chip thickness V f = dynamic f z = variable feed speed per tooth a p = cutting edge length can be fully applied a e = variable n = high Advantages over static trochoidal strategy: - maximum chip volume removal rate - longest tool life - least heat development Due to dynamic analysis and adjustment of feed (by the CAM-System), a constant chip thickness hm and, thus, an equal pressure can be created where the tools can be applied at maximum efficiency. 15

16 Jongen UNI-MILL VHC milling cutter û The mentioned cutting parameters are standard values that may vary depending on processing, type of machine and material grade. 10/16 16 Jongen Werkzeugtechnik GmbH Siemensring Willich Germany Phone: / Fax: / Free Fax: / export@jongen.de Errors, omissions and technical modifications are reserved

Milling tools made by JONGEN! C10 FP 124. Face Milling

Milling tools made by JONGEN! Face Milling C10 FP 124 THE TOOL Especially efficient face milling cutter for the roughing and finishing machining Axial depth of cut max. 5 mm, with 8 effective cutting edges