The best of both worlds

Transcription

1 The best of both worlds CoroMill 210 the ultimate roughing cutter for modern machining techniques Use CoroMill 210 for plunge milling to mill away large volumes of metal or for high feed milling of flat surfaces removing large volumes of chips. It's been developed for both methods without compromise. New to the range is an extra close pitch cutter version providing improved productivity by higher table feed or higher security as cutting data can be maintained. Plunge mill and face mill cutter in one tool. This apparent paradox is made possible through the design of the cutter body, insert seat and the inserts themselves. A ten degree entering angle allows extreme feed rates at small axial depths of cut when the tool is fed tangentially and also high radial depths of cut when fed axially in roughing operations. In both cases the major part of the cutting force is directed towards the spindle, providing a stable cutting action practically free of vibration or deflecting side forces. The inserts are available in two sizes, and have four cutting edges. The CoroMill 210 programme includes modular tools with Coromant Capto or screw mounted couplings, as well as arbor mounted cutters and cylindrical shank cutters. 163

2 CoroMill 210 High feed milling High feed face milling with CoroMill 210 is the most productive roughing method. Extremely high chip volumes can be removed, at feed rates far above those possible with conventional face milling, as the cutting forces are directed towards the spindle even when the tool is operating tangentially. This is true despite the limited depths of cut allowed by the ten degree entering angle max 2,0 mm with the larger 14 mm insert, and 1,2 mm with the smaller. In very favourable conditions feed per insert, f z, up to 4 mm/tooth can be used and metal removal rate values, Q, up to 1400 cm 3 /min can be achieved. a p ic max a p, mm 9 1,2 14 2,0 Do not exceed max a p during high feed rate! Ramping and helical interpolation Ramping In penetrating operations ramping is preferred. The maximum ramping angle is dependent on insert size and cutter diameter. The angle α (alpha) for each cutter is presented in table below. α a p Helical interpolation By using helical interpolation it is possible to produce a hole in a solid workpiece. This is a good solution when required to produce large hole diameters on small machines having limited power availability. Helical interpolation is also one preferred method to change to new Z-level in constant Z-level milling. On holes larger than 50 mm this method with CoroMill 210 is comparable to the productivity of a Coromant U-drill. Hole Cutter dia. ic = 9 mm a p 1,2 mm ic = 14 mm a p 2 mm D 3 25 Insert Max. ramp Hole dia. (mm) Max. ramp Hole dia. (mm) size angle α Min. Max. angle α Min. Max. 9 14, , , , , , , , , , , , , , , When machining a flat surface, maximum width of cut, a e, is determined by D c, see table on page 167. If a larger width of cut is used the cutter will produce a surface with scallops. Due to the nature of these two CoroMill 210 cutters they can often be combined for one and the same workpiece, reducing tool inventory considerably. For example, the main part of a deep die can be roughed out using high feed milling method, three-axis helical engagement 164

3 Plunge milling with CoroMill 210 is the fastest way to mill away large volumes of metal in the axial direction. Repeated plunging of the cutter to a predetermined depth, followed by retraction and repositioning for the next plunge removes metal rapidly through overlapping passes, cutting with the front face of the tool. It is a highly productive method for internal milling of deep cavities, and milling externally along deep shoulders. CoroMill 210 Plunge milling Compared to conventional milling using tool paths in the X-Y plane, the increased rigidity experienced when moving in the Z direction can allow the tool to cut through a larger cross section of material for the same feed rate, resulting in faster metal removal. The considerable axial forces experienced in rough plunge milling mean that optimum performance is obtained with ISO 50 machine tools, or similar. s a e Plunge milling For long tool overhangs and unstable conditions, plunge milling might be the only possible solution. ic max recommended a e, mm max recommended s <0,75 D 3 Programming Avoid using a drilling cycle. Programme path to move away from the wall prior to rapid feed. Best performance is achieved if a smooth exit from workpiece is programmed prior to retraction. = programme table feed = rapid traverse for a continuous transition from one Z-level to another and two axis pocketing (constant Z-level) leaving corner radii larger than cutter radius. The corners can, thereafter, be roughed out using a plunge milling method. <6 Dc Recommended overhang When using long tool overhangs, vibration can occur which will be detrimental to both the machine tool spindle bearings, the tool and the quality of the finished result. CoroMill 210 reduces this risk when rough milling as the major cutting forces act in the Z-plane where the machine tool spindle is generally the strongest, and is a real problem-solver for operations where extended tooling is required. 165

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6 Quick quotation Easy to order Competitive delivery CoroMill R210 Even more possibilities thanks to tailored design! If you do not find what you need in our comprehensive standard programme, choose the tool shape you require and we will tailor it for you to your dimensions. Standard inserts: R , max. a p 1,2 mm R , max. a p 2,0 mm Arbor mounting Coromant Capto Style D 3 l 1 Size D 3 l 1 A ,4-85 C A ,4-85 C A ,4-85 C C C Cylindrical shank Cylindrical shank for power chuck Weldon Size D 3 l 2 D 3 l , , , , ,4-254 Size Size D 3 l ,4-229, ,4-218, ,4-222,5 Coolant holes on all cutters up to diameter 102 mm Options Note For specific details regarding the options, contact your Coromant sales representative. Insert size 9, 14 D 3 9, Diameter mm 14, Diameter mm No of inserts 2 8 depending on cutter diameter and size of inserts Mounting type dm m /D 5m l 3 l 2 l 1 Arbor mounting, Coromant Capto, Cylindrical, Cylindrical power chuck Weldon Mounting size see above Reach length mm Total length see above Programming length see above 168

7 Inserts for CoroMill 210 ic 7 r ε b s l s Insert code Coromant grades P M K R M-PM M-MM M-KM 14 R M-PM M-MM M-KM S H 3040 = Coated carbide (ISO = HC) Dimensions, mm l = ic s r ε b s 9,4 4,0 1,2 1,0 14,5 4,76 1,2 1,0 Ordering example: 10 pieces R M-PM Grades Wear resistance Conditions Good Average Difficult P Steel 3040 M Stainless steel K Cast iron 3040 S Heat resistant and titanium alloys H Hardened materials 3040 Toughness Grade recommendation High feed milling Plunge milling ISO P M K S H Grade Good conditions 1) Difficult conditions ) Good conditions = recommended machining strategies are used, tool overhang = 3 D c ISO P M K S H Grade

8 Cutting data Plunging Feed values Insert f z mm/tooth size ic Starting value (min max) 9 0,10 (0,08 0,15) 14 0,15 (0,10 0,20) Cutting speed recommendations, see Rotating tools catalogue, page A 228 A 235. High feed machining Speed and feed values Material Cutting speed, v c (m/min) Grade recommendations Feed per tooth, f z (mm/z) P M K S H CMC No HB Unalloyed steel Low alloy steel High alloy steel Stainless steel Grey cast iron Nodular cast iron Heat resistant alloys Titanium alloys Hardened steel HRC HRC Insert size 9 Insert size 14 f z rec f z min f z min f z rec f z min f z min 1,5 (0,4 2,0) 1,5 (0,4 2,0) 1,5 (0,4 2,0) 1,0 (0,4 1,5) 1,5 (0,4 1,7) 1,0 (0,4 1,3) 1,5 (0,4 1,7) 1,0 (0,4 1,5) 1,5 (0,4 2,0) 1,5 (0,4 2,0) 0,8 (0,6 1,2) 0,8 (0,6 1,2) 0,8 (0,4 1,2) 0,8 (0,4 1,2) 2,0 (0,4 3,0) 2,0 (0,4 3,0) 2,0 (0,4 3,0) 1,5 (0,4 2,0) 2,0 (0,4 2,5) 1,5 (0,4 2,0) 2,0 (0,4 2,5) 1,5 (0,4 2,0) 2,0 (0,4 3,0) 2,0 (0,4 3,0) 1,0 (0,6 1,5) 1,0 (0,6 1,5) 1,0 (0,4 1,5) 1,0 (0,4 1,5) Caution needs to be taken when high feed milling against a steep wall, reduce feed by 50%. Do not exceed max. a p when high feed milling. If max. a p is exceeded it s necessary to reduce feed by 80%. When recommended machining strategy for machining corners is not followed, feed rate has to be reduced by 50% when machining corners. 170

9 CoroMill the light cutting, high feed facemill for deep cuts and tough conditions CoroMill 245 now with 18 mm inserts This larger version of the successful CoroMill facemill is now introduced to widen the available choice and also to cover more demanding applications. Reinforced cutting edges for six to eight mm deep cuts within a feed range of 0,2 up to 0,6 mm enable the cutter to mill blanks with forging scale and large variations in required depth of cut. Under favourable conditions or reduced cutting data a maximum cutting depth of 10 mm is possible. Like the present smaller version, the new CoroMill is light cutting, making it the power-efficient first choice facemill for most P, M and K materials in the ISO 50 and 60 machining centres. It produces an excellent surface finish particularly when used with wiper inserts. The smaller CoroMill provides ISO 40 and smaller machining centres with an optimum tool, which is also ideal when a mirror finish is required. Both concepts are often problem solvers when unstable conditions prevail and they also provide the reliable performance required to allow tool changes at scheduled intervals. 171

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11 Benchmarks CoroMill 245 Productivity Depth of cut up to 6 mm for the 12 mm insert and up to 10 mm for the 18 mm. Feed per tooth up to 0,42 mm/edge for the 12 mm insert and 0,6 mm for the 18 mm. Available as coarse, close and extra close pitch for maximum performance in different conditions. Long lasting and precision cutter body that resists heavy loads. Secure insert geometries and grades designed by application, make high removal rates a reality. Wiper insert for high productivity with excellent surface finish. Versatility General purpose facemilling in machining centres and small to medium sized milling machines. Capable of both high metal removal and mirror finishing. 45 chamfering. Built-in precision Cutter bodies are machined from prehardened steel resulting high strength and close tolerances. Excellent surface finish, also achieved at high feeds. Precision ground inserts for even greater accuracy. Even more possibilities thanks to tailored design! If you do not find what you need in our comprehensive standard programme, choose the tool shape you require and we will tailor it for you to your dimensions. See the Rotating tools catalogue for information. Safe and easy to use Inserts are self locating. Permanent marking of insert and cutter body with important product information. Tough carbide shim for cutter body protection. Recommended start values for feeds and speeds on the insert box. Operations with 12 and 18 mm inserts = Very good = Good = Fair 12 General face milling Demanding intermittent machining Face milling to mirror finish Machining with long overhang

12 CoroMill 245 Diameter mm Arbor Cylindrical shank Insert 3) size κ r 45 Ordering code Machines: Machining centres, small / medium milling machines Materials: All types Dimensions, mm l 1 = programming length D c Coarse pitch Close pitch Extra close pitch Max KG mm dm 4) m D c2 l 1 l 2 l 3 a p n 5) Differential Even Even max 12 Arbor R Q22-12L 063Q22-12L 3 4 R Q22-12M 063Q22-12M 4 5 R Q22-12H 063Q22-12H 5 6 0,4 0, ,5 75, Q27-12L 4 080Q27-12M 6 080Q27-12H 8 0, , Q32-12L 5 100Q32-12M 7 100Q32-12H 10 1, , Q40-12L 6 125Q40-12M 8 125Q40-12H 12 2, , Q40-12L 7 160Q40-12M Q40-12H 16 5, , Q60-12L 8 200Q60-12M Q60-12H 20 6, , Q60-12L Q60-12M Q60-12H 24 8, , Cylindrical 2) 32 R A32-12M 1) 3 0, , R A32-12L 3 0, , A32-12L 3 R A32-12M 4 0, , A32-12L 4 063A32-12M 5 1, , A32-12L 4 080A32-12M 6 1, , D Close pitch Extra close pitch c Max KG mm Differential Differential dm 4) m D c2 l 1 l 2 l 3 a p n 5) max 18 Arbor 80 R Q32-18M 1) 4 R Q32-18H 1) 5 1, , Q32-18M 1) 4 100Q32-18H 1) 6 1, , Q40-18M 5 125Q40-18H 7 2, , Q40-18M 6 160Q40-18H 9 4, , Q60-18M 8 200Q60-18H 12 6, , Q60-18M Q60-18H 14 11, , ) Without shim. 2) For use in power chucks. 3) Inserts are ordered separately. 4) Mounting dimensions, see Rotating Tools catalogue, page A ) n max (max. rev/min) for holders must also be considered. Ordering example: 2 pieces R Q22-12L Spare parts Cutter Insert size (15IP) 3, (15IP) 3, (3,5) (20IP) 5, (20IP) 5, (5,0) 174 D c mm Insert screw Key (Torx Plus) Torque value Nm Shim Shim screw Key (mm) Ordering example: 10 pieces

13 CoroMill 245 Improve your productivity Light Medium Heavy Insert size 12 mm Extra positive M Reinforced cutting edge CoroMill inserts have been developed to suit a range of material groups and operations. Correctly applied with the right cutting data, the productivity improvement is far beyond what any general type of insert can offer. L H Light machining. Low cutting forces. Low feed rates. Insert size 18 mm Heavy chip removal rates. Variations in depth of cut General use in most materials M Heavy machining. Highest edge security High feed rates. The insert identity is permanently marked on the inserts with geometry, grade, nose radius and cutting edge identity and from the ordering code you will be able to select the right insert for your application. Example: R T6 E-PL L = Light cutting geometry (L) P = Workpiece material steel (ISO P) E = Highest edge sharpness and precision Cutting edge length Surface roughness Wiper insert The extended land of the wiper insert allows the feed per revolution to be increased by up to four times the normal maintaining surface quality, especially when using larger cutter diameter. It is normally enough to use only one wiper insert. To obtain the best performance, the wiper insert should be combined with the precision ground insert but combinations with direct pressed inserts may, in many cases, also give a satisfactory result. f n = feed/revolution b s2 Without wiper insert f n1 = b s1 f n2 = b s2 With wiper insert b s1 Feed Basic grades for CoroMill 245 Wear resistance Conditions Good Average Difficult P Steel CT M Stainless steel CT 530 K Cast iron CB CC6090 H13 A K20W N Aluminium / Non-ferrous CD10 H10 S Heat resistant and titanium alloys H Hardened materials CT 530 CB50 Toughness For grade description, see Rotating Tools catalogue, page E 12 - E

14 Inserts for CoroMill 245 Cemented carbide / Cermet Light Medium Heavy Aluminium Wiper The Wiper inserts can also be used for Turn-Milling. See Rotating Tools catalogue, page A 43 for more information. E = Highest edge sharpness and precision K = Highest edge sharpness M= Highest edge security HEAVY MEDIUM LIGHT Coromant grades P M CB K20W H13A 12 R T3 E-PL 12 T3 E-ML 12 T3 E-KL R T3 M-PL 12 T3 M-KL Wiper R T3 E-W 12 R T3 M-PM 12 T3 M-KM 12 T3 K-MM 18 R T6 M-PM 18 T6 M-KM 18 T6 M-MM Wiper R T6 E-W 12 R T3 M-PH 12 T3 M-KH K N CT CT CB CC CD CT Dimensions, mm l = ic s b s l a r ε 13,4 3,97 2,1 10 1,5 S H CD10 H = Coated carbide/cermet (ISO = HC) CT = Cermet (ISO = HT) = Uncoated carbide (ISO = HW) 13,4 3,97 8,2 10 1,5 13,4 3,97 2,0 10 1,5 18,0 6,1 1,5 13,9 1,0 18,0 6,1 10,8 13,9 1,0 13,4 3,97 2,0 10 1,5 Aluminium machining 12 R T3 E-AL For grade description, see Rotating Tools catalogue, pages E 12 - E ,4 3,97 2, Ordering example: 10 pieces R T3 E-PL 530 Cutting speed recommendations, see Rotaling Tools catalogue, pages A 228 A 235. Recommended feeds Insert geometry f z ( feed in mm/tooth) Starting value (min max.) LIGHT Insert size 12 mm E- PL 0,14 (0,08 0,21) 4030, 3020,, ML 0,11 (0,07 0,17) CT530, H13A } KL 0,09 (0,05 0,12) M-PL 0,17 (0,08 0,21) KL MEDIUM M-PM, M-KM 0,24 (0,10 0,28) M-PM, M-KM 0,12 (0,08 0,18) CT530, H13A K- MM 0,23 (0,10 0,28) HEAVY M-PH, M-KH 0,35 (0,10 0,42) Aluminium machining E-AL 0,24 (0,10 0,28) Insert geometry f z ( feed in mm/tooth) Starting value (min max.) Insert size 18 mm MEDIUM M-PM 0,35 (0,15 0,50) M-KM 0,35 (0,15 0,50) M-MM 0,35 (0,15 0,50) 176

15 Inserts for CoroMill 245 Ceramic Boron nitride tipped Two cutting edges Wiper Polycrystalline diamond tipped The Wiper inserts can also be used for Turn-Milling. See Rotating Tools catalogue, page A 43 for more information. One cutting edge Wiper E = Highest edge sharpness and precision K = Highest edge sharpness M= Highest edge security Max a p mm Coromant grades P M CB K20W H13A CD10 H K CT CT CB CC CD CT Dimensions, mm l = ic s b s l a r ε N S H CC = Ceramics (ISO = CA, CM, CN, CC) CB = Boron nitride (ISO=BN) CD = Polycrystalline diamond (ISO = DP) Ceramics 12 R T3 E 6,0 13,4 3,97 0,4 10 2,5 Cubic boron nitride 12 R T3 E 2,5 Wiper R T3 E-W 2,5 Polycrystalline diamond 12 R T3 E 2,5 Wiper R T3 E-W1 2,5 13,4 3,97 1,4 1,5 13,4 3,97 6,4 2,5 13,4 3,97 1,4 1,5 13,4 3,97 6,4 2,5 Ordering example: 10 pieces R T3 E 6090 For grade description, see Rotating Tools catalogue, pages E 12 - E 17. Cutting speed recommendations, see Rotaling Tools catalogue, pages A 228 A 235. Recommended feeds f z ( feed in mm/tooth) Starting value (min max.) Ceramics E 0,21 (0,10 0,30) CC6090 Cubic boron nitride E 0,14 (0,07 0,21) CB50 Polycrystalline diamond E 0,14 (0,07 0,21) CD10 The torque wrench for Torx Plus screws ensures you always have the correct torque value, both in the workshop and in the tool room. Correct torque values are vitally important when clamping ceramic and cubic boron nitride inserts. Always use protective goggles when using ceramic inserts. For keys, see page

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17 CoroMill 300 Light cutting and versatile High performance for milling a wide range of different materials is only one of the many advantages CoroMill 300 can offer especially because of its light cutting action. Often it is a problem solver in difficult to cut materials. The novelties being introduced now are cutters carrying 16 mm inserts - a concept offering optimal security even for machining at high table feeds. Low cutting forces considerably limit the cutters disposition for vibration - also when used at high cutting data. The cutters power efficiency contributes to the capability of all machine tools. CoroMill 300 is the universal choice for all milling and Multi Task machine tools and the first choice for ISO 40 spindles. Extra close pitched cutters with an optional amount of small inserts have a capability of reaching unbeatable productivity when used in HSM together with extreme table feeds. Light cutting for performance and versatility Power efficiency both in stable and weak machines High and vibration free metal removal with both short and long tools Smooth cutting action in all materials Pitch and insert options combined for productivity in every operation 179

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20 Ramping and helical interpolation l m tan α Ramping In penetrating operations ramping is preferred. The maximum ramping angle is dependent on insert size and cutter diameter. The angle α (alpha) for each cutter is presented in table below. a p D 3 Hole ic a p Helical interpolation By using helical interpolation it is possible to produce a hole in a solid workpiece. This is a good solution when required to produce large hole diameters on small machines having limited power availability. Dia. D 3 Max. ramp angle α ic = 8 mm a p 5 mm Min. dist. 1) l m (mm) Hole dia. (mm) Min. Flat bottom Max. 25 8,0 42, ,0 68, ,0 76, ,5 98, ,0 98, ,5 137, ,0 137, ,5 171, ,5 171, ,0 229, ) Maxmimum α and a p Dia. D 3 Max. ramp angle α ic = 12 mm a p 6 mm Min. dist. 1) l m (mm) Hole dia. (mm) Min. Flat bottom Max ,0 26, ,0 30, ,5 32, ,0 40, ,5 44, ,5 59, ,0 62, ,5 81, ,5 88, ,5 114, ) Maxmimum α and a p Cutters with threaded coupling (neutral design) Dia. D 3 Max. ramp angle α ic = 10 mm a p 5 mm Min. dist. 1) l m (mm) Hole dia. (mm) Min. Flat bottom Max ,0 23, ,3 27, ,3 34, ,7 37, ) Maxmimum α and a p Dia. D 3 Max. ramp angle α 1) Maxmimum α and a p ic = 12 mm a p 6 mm Min. dist.1) l m (mm) Hole dia. (mm) Min. Flat bottom Max ,0 16, ,9 19, ,2 25, ,1 28, a e ic max rec. a e, mm Plunge milling For long tool overhangs and unstable conditions, plunge milling might be the only possible solution. 8 7, ,8 ic max rec. a z, mm 8 1,7 10 3,3 12 3,3 Good practice for plunge milling with round inserts is to use radial depths of cut, a e, of approx. 80% of insert diameter, ic. That will give a stabilising effect of the tool. Peck drilling Pocketing can also be performed to a limited extent, by peck-drilling at depths of up to 1,5 mm depending on insert size. 182

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