Keeping the Customer First. Tungaloy Catalogue TE0707-E2. Cutting Tools.

Transcription

1 Keeping the Customer First Tungaloy Catalogue TE0707-E Cutting Tools

2 Selection Guides List of Selection Guides Specifications Solid Carbide s For High Speed Deep Hole ing of Steels () TAC For Steel, Stainless steel, Cast Irons ()

3 410 List of - Part 1 - For steels Operation Tool name Type Appearance Work materials Carbon steels Alloy steels Mild steels Stainless steels L/D diameter range (mm) General drilling Spiral jet drills for steels TAC drills 3,5,8 2,3 4,5 ø 12.5 ø 3.0 ø 20 ø54 highest productivity, maximum performance Advantages/Applications Wide product range - 2, 3, 4 and 5xd for different bore hole depths - 4 different high performance cutting grades - 3 different chipbreaker geometries - Wiper - technology - Inserts with 4 cutting edges - Suited for minimum quantity lubricating - Eccentric sleeve Low vibration and low noise drilling of most different cutting materials High cutting parameter, reduced machining time Peripheral insert Centre insert Exchangeable best suitable usable Specially designed chip pocket helps effectively to remove chips produced by the centre cutting edge Comparison of tool life Cutting speed: Vc = 1 m/min Competitor B A C 0.1 -DS (AH120) Frank waer resistance VB (mm) Cutting length (m) Cutting speed: Vc = 220 m/min Competitor B C A -DS (AH120) Cutting length (m) Frank waer resistance VB (mm) Work material: Stainless steel (X5CrNi189) : ø19, L/D = 3 Insert: -DS AH120 Machine: Machining centre Feed rate: f = 0.08 mm/rev ing depth: 25 mm (Counter hole) Coolant: Emulsion Surface quality Surface quality Ra (µm) Comparison of wear 9 Competitor A Feed rate: f = mm/rev Cutting length: 5.2 m Competitor B DW -DW Competitor A Competitor B Feed rate f (mm/rev) Work material: Ck55 Machine: Machining centre : ø22, L/D = 2 Coolant: Emulsion Cutting speed: Vc = 100 m/min

4 List of 411 Type of Attainable surface Type coolant IT class roughness Features Page supply (Rmax) 9 ~ ~ 25 Coated solid drills with spiral oil holes. Excels in high-speed deep-hole drilling ~ 12 ~ Indexable-insert drills. Four-corner insert design for economical drilling. Excellent chip evacuation. 419 Solid carbide drill Highest precision in detail for process stable applications New basic substrate for more rigidity New Flash coat technology Large flutes for optimal chip flow Innovative TiAlN based coating technology Linear main cutting edge for easy regrinding 3 x d, 5 x d and 8 x d A B Ra = 0.1 µm conventional Tool life Suitable for minimum quantity lubrication Wear Feed f (mm/rev) : ø8.0 Work material: Ck45 (235HB) Machine: Horizontal machining centre Vc: 88 m/min ing depth: mm Coolant: Emulsion Competitor A B C D E F Nach efter 81 mm Cutting length (m) : ø8.0 (L/D = 5) Vc: 1 m/min Work material: Ck55 (210HB) f: mm/rev Machine: Vertical machining ing depth: mm centre Coolant: Emulsion (20 bar) Cutting edge wear (mm) efter after 53 mm Cutting length (m) : ø8.0 (L/D = 5) Vc: 80 m/min Work material: 42CrMo4 (230HB) f: mm/rev Machine: Competitor A Vertical machining centre ing depth: mm Coolant: Emulsion (20 bar)

5 412 ing Tool Selection Guide For drilling steels Low to medium carbon steels (USt42-2, Ck45 ~ Ck55), alloy steels (15CrMo5 ~ 42CrMo4) Hole depth: L/D = 2 diameter ø12.5 ~ 54 Hole depth: L/D = 3 Tolerance requirements Low Coolant supply system ø3 ~ 20 IT: 9 ~ 10 ø12.5 ~ 54 Low Hole depth: L/D = 4 ø12.5 ~ 54 Low Hole depth: L/D = 5 ø12.5 ~ 54 Low ø3 ~ 20 IT: 9 ~ 10 Hole depth: L/D = 8 ø3 ~ 20 IT: 9 ~ 10 No. of revolutions n (rpm) = Cutting speed Vc (m/min) x ø (mm) Table feed Vf (mm/min) = n (rpm) x Feed f (mm/rev)

6 ing Tool Selection Guide 413 ing Tool Selection Guide For drilling cast irons and light alloys Grey cast irons (GG20 ~ GG35), ductile cast irons (GGG ~ GGG60), aluminium alloys Hole depth: L/D = 2 diameter ø12.5 ~ 54 Hole depth: L/D 3 Tolerance requirements Low Coolant supply system ø12.5 ~ 54 Low Hole depth: L/D = 4 ø12.5 ~ 54 Low Hole depth: L/D = 5 ø12.5 ~ 54 Low

7 414 ing Tool Selection Guide For drilling difficult-to-cut materials Hard materials: Hardened steels (XCrMoV5-1), high-manganese steels, etc. Heat resisting alloys: Inconel 718 etc. Titanium alloys: Ti-6Al-4V etc. Hole depth: L/D = 3, 5, 8 diameter ø3 ~ 20 Tolerance requirements IT: 9 ~ 10 Coolant supply system Thread sizes and applicable drill diameter for pre-drilling before tapping When using Spiral-Jet drills for pre-drilling of tapping holes, refer to the following table to select proper drill diameter. Nominal thread size Metric coarse thread Inner diameter of second class thread (mm) max. min. Applicable drill diameter for types ød (mm) Applicable drill diameter for HSS drills (mm) M M M M M M M M M Nominal thread size Metric coarse thread Inner diameter of second class thread (mm) Applicable drill diameter for types ød (mm) Applicable drill diameter for HSS drills (mm) max. min. M M M M M M M M M No. of revolutions n (rpm) = Cutting speed Vc (m/min) x ø (mm) Table feed Vf (mm/min) = n (rpm) x Feed f (mm/rev)

8 ing Tool Selection Guide 415 Application Ranges of For steels For cast irons, light alloys L/D ratio L/D ratio diameter (mm) diameter (mm)

9 416 Specification Giga Jet Specifications Solid carbide, coated drills with spiral oil holes Standard stock in Europe Standard stock in Japan 1 ød h8 ød h6 l2 l1 L/D = 3 L ød ød L l1 l2 0300F F F F F03 03F F F F F03 00F F F F F03 04F F F F F03 00F F F F F03 05F F F F F F F F F F03 06F F F F F F F F F F03 07F F ød ød L l1 l2 0770F F F F F F F F03 08F F F F F F F F F F03 09F F F F F F F F F F03 10F F F F F F F F F F03 11F F F F F F F F F03 ød ød L l1 l2 12F03 12F F F F F F F F F03 13F03 13F F F F F03 10F F F F03 14F03 14F F F F F03 10F F F F03 15F03 15F F F F F F03 16F F03 17F F03 18F F03 19F F

10 Solid carbide drill 417 Standard stock in Europe Standard stock in Japan 1 ød h8 ød h6 l2 l1 L/D = 5 L ød ød L l1 l2 0300F F F F F05 03F F F F F05 00F F F F F05 04F F F F F05 00F F F F F05 05F F F F F F F F F F05 06F F F F F F F F F F05 07F F ød ød L l1 l2 0770F F F F F F F F05 08F F F F F F F F F F05 09F F F F F F F F F F05 10F F F F F F F F F F05 11F F F F F F F F F ød ød L l1 l2 12F05 12F F F F F F F F F05 13F05 13F F F F F05 10F F F F05 14F05 14F F F F F05 10F F F F05 15F05 15F F F F F F05 16F F05 17F F05 18F F05 19F F

11 418 Standard stock in Europe Standard stock in Japan 1 ød h8 ød h6 l2 l1 L/D = 8 L ød ød L l1 l2 0300F08 03F08 00F F08 00F08 05F F08 06F F ød ød L l1 l2 07F F08 08F F F F08 10F F08 11F ød ød L l1 l2 1200F08 12F F08 13F08 10F08 14F08 10F08 15F F Cutting conditions Work material Mild steel, Low carbon steel (< 200HB) USt.42-2, Ck25 Carbon steel, Alloy steel (< 300HB) Ck45, 42CrMo4 Stainless steel (ferritic-martensitic) X5CrNi18-10 Grey cast iron GG25 ø3.0 - ø6.0 ø6.0 - ø10.0 ø ø16.0 ø ø20.0 ø3.0 - ø6.0 ø6.0 - ø10.0 ø ø16.0 ø ø Cutting speed Vc (m/min) Feed f (mm/rev) Ductile cast iron GGG70 Aluminium alloys Titanium alloys TiAl6V3 Difficult-to-cut materials Inconel Hardened steel (< 45HRC)

12 Info Regrinding Procedures Regrinding method (applied to ) Before regrinding: Check the cutting edge for damage and wear. If any large fracture is found, remove it with a silicon carbide wheel. (1) Grinding the flank type for steels Use a 280 to 0 grit diamond cup-type wheel of 100 to 200 mm in diameter. (1) Grind the relief surface so that primary relief angle of θ2 can be formed as shown in Fig. 1. After grinding the other side likewise, do sparkout grinding so that the difference of the lip heights will be kept within 0.02 mm. Primary relief Secondary relief Point angle (2) In the case of type for steels: Turn the drill by θ4 and secure it there. Then grind secondary relief surface so that secondary relief angle of θ3 can be formed while taking care to bring the ridge line formed between the primary and secondary relief surfaces to the drill center (values of θ1 to θ4 are shown in Table1). Using points A and B as reference, obtain level. Primary relief angle type θ1 (Point angle) Table 1 θ2 (Primary relief angle) θ3 (Secondary relief angle) θ4 (Rotating angle) Fig. 1 Grinding relief angle ~ ~ (2) Thinning Use a 280 to 0 grit diamond straight-type wheel of 100 to 200 mm in diameter. Conduct thinning in the same manner as cross thinning (X-type). For type drills, take care to leave the part of secondary relief by 0.05 to 0.1 mm as shown in Fig. 2. Values of β1 to β3 written in the Figures are given in the Table 2. type (Fig. 2) Table 2 β1 β2 β3 R 1 ~ ~ ~ 112 β2 β1 0 β3 Fig. 2

13 Info (3) Honing R θß Relief face Fig. 3 T R0.01 ~ 0.02 Rake face A - A section The honing angle θ and width T should be varied depending on the drill type, diameter and work material. Recommended honing specifications are given in the Table below. Honing procedures (refer to Fig. 3) Round the R portion shown in Fig. 3 in large. Then roughly hone the cutting edge lines by using an electro-deposited diamond file of around 170 grit. Carry out finish honing by using a diamond hand stick of 0 to 600 grit. For type drills, there is no need to hone the thinned portions. The honing width should be changed depending on the drill diameter. For smaller side of diameter, the width should be in smaller side of values given in the Table. Honing specifications for Round the R portion in large (mm) ~ ø6 ø6 ~ ø12 ø12 ~ ø20 Mild steels θ T 0.08 ~ ~ ~ 0 Hard steels θ T 0.05 ~ ~ ~ 0.15 After regrinding, check the following before use: The difference of the lip heights is kept within 0.02 mm. There is no damaged portion on the cutting edges left. Cutting edges are properly honed. No grinding burrs left.

14 TAC s for Steels, Cast Irons and Aluminium Alloys 419 For General ing of Steels, Cast Irons and Aluminium Alloys TAC drills Specifications Indexable insert drills with oil hole Max. drilling depth For L/D 2 (Whistle notch type shank) ød (mm) L025W L026W L027W20-2 1L028W L029W20-2 1L030W L031W L032W L033W L034W L035W L036W L037W L038W L039W L0W L041W L042W L043W L044W L045W L046W L047W25-2 2L048W L049W25-2 2L0W L051W L052W L054W L056W L058W L060W L062W L064W L066W-2 3L068W-2 3L070W-2 360L072W-2 370L074W-2 380L076W-2 390L078W-2 0L080W-2 410L082W-2 420L084W-2 430L086W-2 4L088W-2 4L090W-2 460L092W-2 470L094W-2 480L096W-2 490L098W-2 0L100W-2 510L102W-2 520L104W-2 530L106W-2 5L108W-2 Note: L/D = Hole depth / diameter ød ød R R L Applicable insert XPMT0104R-** XPMT0204R-** XPMT06X308R-** XPMT07H308R-** XPMT08T308R-** XPMT110412R-** XPMT1512R-** Max. Offset + (mm) Clamp screw Torx wrench Hex. wrench -2-2L0-2.2R T-6D T-7D T-8D T-9D T-15D T-20D P-5 P-6 Plug screw 1/8-28 PT1/4GN

15 420 R1 L ød1 ød2 R L038W20 130L039W20 135L041W20 1L042W20 145L044W20 1L045W20 155L047W20 160L048W20 165L0W20 170L051W20 175L053W25 180L054W25 185L056W25 190L057W25 195L059W25 200L060W25 205L062W25 210L063W25 215L065W25 220L066W25 225L068W25 230L069W25 235L071W25 2L072W25 245L074W25 2L075W25 255L077W25 260L078W25 270L081W32 280L084W32 290L087W32 300L090W32 310L093W32 320L096W32 330L099W 3L102W 3L105W 360L108W 370L111W 380L114W 390L117W 0L120W 410L123W 420L126W 430L129W 4L132W 4L135W 460L138W 470L141W 480L144W 490L147W 0L1W 510L153W 520L156W 530L159W 5L162W XPMT0104R-** XPMT0204R-** XPMT06X308R-** XPMT07H308R-** XPMT08T308R-** XPMT110412R-** XPMT1512R-** L0-2.2R T-6D T-7D T-8D T-9D T-15D T-20D P-5 P-6 1/8-28 PT1/4GN For L/D 3 (Whistle notch type shank) Max. drilling depth Note: L/D = Hole depth / diameter Applicable insert Clamp screw Torx wrench Hex. wrench Plug screw ød (mm) Max. Offset + (mm)

16 TAC s for Steels, Cast Irons and Aluminium Alloys 421 Max. drilling depth For L/D 4 (Whistle notch type shank) ød (mm) L0W L052W L054W20-4 1L056W L058W20-4 1L060W L062W L064W L066W L068W L070W L072W L074W L076W L078W L080W L082W L084W L086W L088W L090W L092W L094W25-4 2L096W L098W25-4 2L100W L102W L104W L108W L112W L116W L120W L124W L128W L132W-4 3L136W-4 3L1W-4 360L144W-4 370L148W-4 380L152W-4 390L156W-4 0L160W-4 410L164W-4 420L168W-4 430L172W-4 4L176W-4 4L180W-4 460L184W-4 470L188W-4 480L192W-4 490L196W-4 0L200W-4 510L204W-4 520L208W-4 530L212W-4 5L216W-4 Note: L/D = Hole depth / diameter ød1 ød2 R1 R L Applicable insert XPMT0104R-** XPMT0204R-** XPMT06X308R-** XPMT07H308R-** XPMT08T308R-** XPMT110412R-** XPMT1512R-** Max. Offset + (mm) Clamp screw Torx wrench Hex. wrench -2-2L0-2.2R T-6D T-7D T-8D T-9D T-15D T-20D Plug screw

17 422 R1 L ød1 ød2 R L063W L065W L068W20-5 1L070W L073W20-5 1L075W L078W L080W L083W L085W L088W L090W L093W L095W L098W L100W L103W L105W L108W L110W L113W L115W L118W25-5 2L120W L123W25-5 2L125W L128W L130W L135W L1W L145W L1W L155W L160W L165W-5 3L170W-5 3L175W-5 360L180W-5 370L185W-5 380L190W-5 390L195W-5 0L200W-5 410L205W-5 420L210W-5 430L215W-5 4L220W-5 4L225W-5 460L230W-5 470L235W-5 480L2W-5 490L245W-5 0L2W-5 510L255W-5 520L260W-5 530L265W-5 5L270W XPMT0104R-** XPMT0204R-** XPMT06X308R-** XPMT07H308R-** XPMT08T308R-** XPMT110412R-** XPMT1512R-** L0-2.2R T-6D T-7D T-8D T-9D T-15D T-20D Applicable insert Clamp screw For L/D 5 (Whistle notch type shank) Torx wrench Hex. wrench Plug screw Note: L/D = Hole depth / diameter Max. drilling depth ød (mm) Max. Offset + (mm)

18 TAC s for Steels, Cast Irons and Aluminium Alloys 423 Inserts -DJ Breaker -DS Breaker -DW Breaker Wiper Cat No. XPMT0104R-DJ XPMT0204R-DJ XPMT06X308R-DJ XPMT07H308R-DJ XPMT08T308R-DJ XPMT110412R-DJ XPMT1512R-DJ Cat No. XPMT0104R-DS XPMT0204R-DS XPMT06X308R-DS XPMT07H308R-DS XPMT08T308R-DS XPMT110412R-DS XPMT1512R-DS Cat No. XPMT0104R-DW XPMT0204R-DW XPMT06X308R-DW XPMT07H308R-DW XPMT08T308R-DW XPMT110412R-DW XPMT1512R-DW Grades Applicable drill AH7 T1015T313W A B s ød R diameter ø12.5 ~ ø ø15.0 ~ ø ø17.5 ~ ø ø22.0 ~ ø ø26.5 ~ ø ø33.0 ~ ø ø42.0 ~ ø54.0 Grades Applicable drill AH120 A B s ød R diameter ø12.5 ~ ø ø15.0 ~ ø ø17.5 ~ ø ø22.0 ~ ø ø26.5 ~ ø ø33.0 ~ ø ø42.0 ~ ø54.0 Grades Applicable drill AH120 GH730 A B s ød R diameter ø12.5 ~ ø ø15.0 ~ ø ø17.5 ~ ø ø22.0 ~ ø ø26.5 ~ ø ø33.0 ~ ø ø42.0 ~ ø54.0 Standard cutting conditions Work materials Carbon steels (C > ) St37, C25E Alloy steels (C > ) C45, C55 Mild steels 15CrMo5 Alloy Steels 42CrMo4 Stainless steels (Austenitic type) X5CrNi18-10 Stainless steels (Ferric and Martensitic type) X3CrMnNiN Stainless steels Precipitation hardening type) X2CrNiMoN Grey cast iron GG25 Ductile cast iron GGG70 Aluminium alloys AH120 AH7 T1015 GH730 -DS -DW -DS -DW -DS -DW -DS -DW -DS -DW Grade / Breaker Notes: - When using the -DW chipbreaker to achieve better surface qualities, cutting parameter as in above table should be used. Cutting speed Vc (m/min) DJ -DW DJ -DW No. of revolutions n (rpm) = Cutting speed Vc (m/min) x ø (mm) Table feed Vf (mm/min) = n (rpm) x Feed f (mm/rev) L/D ø12.5 ~ ø14.5 ø15.0 ~ ø17.0 Feed f (mm/rev) ø17.5 ~ ø26.0 ø27.0 ~ ø32.0 ø33.0 ~ ø54.0 2D - 5D D, 3D D, 5D D - 5D D, 3D D, 5D D - 5D D - 5D D - 5D D, 3D DJ -DW D, 5D D, 3D DJ -DW D, 5D D, 3D DW D, 5D When using the -DW chipbreaker to achieve higher productivity, feed rate should be multiplied by. - For work materials of < HRC, feed rate should be set to %. - For smaller drill dia, choose the lower recommended parameter. - Water soluble coolant is recommended, cutting fluid should be supplied through the tool. - A minimum fluid quantity of 7 l/min for 2 and 3xd rev. 10 l/min for 4 and 5xd is recommended.

19 424 EZ Eccentric Sleeve Hole diameter adjustment at the milling machine Centre-height adjustment at the turning lathe With the EZ sleeve, the hole size can be adjusted from +0.6 mm larger to - mm smaller With the EZ sleeve, the centre-height can be adjusted from + mm to - mm Scale for the milling machine Scale for the turning lathe Specifications L1 L4 L3 ød1 ød2 ød3 L2 ø D1 ø D2 ø D3 L1 L2 L3 L4 Milling machine drill ø Turning lathe Centre-height EZ2025L ~ - + ~ EZ2532L ~ - + ~ EZ32L ~ - + ~ EZL ~ - + ~ -0 Hex. wrench P-2.5 * ø D1 equal to EZ sleeve ø D1

20 EZ Eccentric Sleeve 425 Applications Hole diameter adjustment at the milling machine 1. Adjust the scale at the flange periphery of the EZ sleeve to the centre of the clamping screws Scale Centre-height adjustment at the turning lathe Most of the troubles at the turning lathe are based on the centreheight deviation. The centreheight is appropriate if the core of approximately mm diameter remains at the centre of the end face. Centre-height adjustment is necessary for the following cases: - No core remaining - Core diameter is more than 1 mm. Core ø mm is normal EZ eccentric sleeve 2. For a larger hole diameter, rotate the sleeve to the + direction; for a smaller hole diameter, rotate the sleeve to the - direction The illustration shows the example of adjusting the hole diameter + mm. Clamping screw A (to fix the drill) 1. Set the drills so that the outer insert s face becomes parallel to the X-axis of the tool turret. Adjust the scale (for the lathe) at the flange face of the EZ sleeve to the centre of the clamping screws. EZ eccentric sleeve Clamping screw B (to fix the sleeve ) Scale EZ eccentric sleeve Scale + + Clamping screw A (to fix the drill) Clamping screw B (to fix the sleeve) 2. When no core remains, rotate the EZ sleeve to + direction; when core diameter is more than 1 mm, rotate to - direction. X-axis (-) (+) 3. When rotating the EZ sleeve, insert the wrench into the hole at the flange periphery and rotate the EZ sleeve. Screws A + B have to be loosened. 4. Secure the drill by screw A. Secure the EZ sleeve by lightly tightening screw B. Tighten screw B only lightly, otherwise EZ sleeve can be damaged! Note: Cannot be used for collect chuck holder. Over L/D 4 or bigger adjustment, please reduce feed rate. For smaller adjustment, the drill itself will interfere with the hole diameter. It is recommended that hole diameter should be adjusted to a larger diameter than the drill diameter.