5230VS Series. Chevron Long Edge Milling Cutter (Porcupine)

Transcription

1 5230VS Series Chevron Long Edge Milling (Porcupine) Shoulder / Profiling / Slotting HIGH PERFORMANCE LONG EDGE MILLING CUTTERS The Stellram 5230VS09 and VS12 Series is perfectly quali ed for pro ling and full slotting. Designed for high material removal rates in Titanium and High Temperature Alloys. Several applications have shown metal removal rates of up to two times greater than the previous operating cutting parameters. The advanced Chevron design ensures that one cutting point is always in contact with the material during entrance and exit. This provides optimum harmonic stability - resulting in maximum tool life and a 30% improvement in surface nish. A generous ute capacity coupled with each individual cutting edge having its own jet of coolant, provides for excellent chip evacuation. This works to further enhance surface nish and increases metal removal rates to a higher level of productivity. The advanced 5230VS series is ideal for rough machining of, Alloyed, Stainless and particular for Titanium and High Temperature Alloys. Insert positioning provides smooth progressive penetration and cutting action for extended tool life. Individual coolant jets to each insert provides constant chip evacuation and temperature stability in the cutting zone. The advanced Chevron design improves stability and lowers power consumption, increasing tool life up to 2 times greater than comparable cutter in today s market. Proven versatility in a wide application area in Titanium and High Temperature Alloys increasing productivity. 5230VS09: (ap max is determined by selection of Diameter) Diameter Range and Maximum ap = 50mm Dia. with ap 51mm or 80mm 5230VS12: (ap max is determined by selection of Diameter) Diameter Range and Maximum ap = 63mm Dia. with ap 57mm or 94mm 80mm Dia. with ap 65mm or 110mm 100mm Dia. with a p 76mm or 133mm 179

2 5230VS09 Chevron Long Edge Milling (Porcupine) d 1 Slotting H a p max Product Dimensions (mm) Spares EDP Item Description D L/H l1 d1 ap max ap max No. of Slotting* No. of 5230VS09 Shell Mill Fixation VS09-A050Z4R F3508T T15 2, VS09-A050Z4R F3508T T15 2,10 * Note: Please do not surpass the recommended max. ap for slotting. EDP EDP Screw Tightening Nm D Shell Mills are supplied with inserts screws, coolant control screws, steel coolant plug, nord-lock washer and mounting screw. Shell Mill Fixation 5230VS09 Spare Parts Coolant Control Screw Screwdriver Coolant Plug Screw EDP Screw Qty. EDP EDP 5230VS09-A050Z4R SB F3006T T9 5230VS09-A050Z4R SB-3621 Coolant Plug tightening Nm VS09 Torque Values and Spare Parts 5230VS09-A050Z4R VS09-A050Z4R80 Mounting Bolt EDP EDP Normal Condition NLW M ISO x 30mm SHCS ** Torque values for mounting bolts. Excessive condition is when long reach extensions are required or when cutting parameters are elevated to extreme parameters. EDP 5230VS09 Technical Information (mm) Product Dimensions Item Description Facing Pitch Ramping Angle Helical Hole min. - max. ap max Helical / Linear Max RPM VS09-A050Z4R VS09-A050Z4R Flat Facing Pitch 180

3 5230VS09 d r SDHT SDHT SDMT09-41 SDMW09-TN Product Application & Material Dimensions (mm) Roughing Semi-Finishing Finishing l s EDP Item Description Grade Depth of Cut (mm) ap max* or ap max. and ap min. - max. ae max.* ae max. 15% D** d (IC) l r hm min SDHT09T308EN-422-9,52 9,52 3,97 0,80 0, SDHT09T308EN-422-9,52 9,52 3,97 0,80 0, SDHT09T308EN ,52 9,52 3,97 0,80 0, SDHT09T308EN-423-9,52 9,52 3,97 0,80 0, SDMT09T308EN-41-9,52 9,52 3,97 0,80 0, SDMT09T308EN-41-9,52 9,52 3,97 0,80 0, SDMT09T308EN-41 MP91M - 9,52 9,52 3,97 0,80 0, SDMW09T308TN - - 9,52 9,52 3,97 0,80 0, SDMW09T308TN - - 9,52 9,52 3,97 0,80 0, SDMW09T308TN MP91M - - 9,52 9,52 3,97 0,80 0,15 Machining Choice: 1 Choice 2 nd Choice 3 rd * Note: Please do not surpass the recommended max. a p for slotting as shown on the steel body page 180. * Note: a p max. for pro ling is only possible when a e < 75% of the Diameter. ** Note: For semi nishing, axial engagement a p for slotting and radial engagement ae for pro ling should be max. 15% of the Diameter. SDHT09T308EN-423 to be used in unstable conditions. Note: Feed recommendations can be found on page 182. Speed recommendations can be found on page

4 5230VS VS09 Feeds f z Geometry Grade Operation Unalloyed Alloyed Refractory PH Gray Iron Spheroidal- Ductile Iron Malleable Iron Aluminium & <16% Si 116 HBN Aluminium & Silicon >16% Si 92 HBN HTA Iron HTA Cobalt HTA Nickel HTA Titanium Hard >415 HBN >400 HBN EN-422 EN-422 EN-423 EN-423 EN-41 EN-41 EN-41 TN TN TN MP91M MP91M Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max ,05-0,13 0,05-0, ,05-0,08 0,05-0,08 0,05-0,10 0,05-0, Slotting - - 0,04-0,11 0,04-0, ,05-0,07 0,05-0,07 0,05-0,08 0,05-0, ,05-0,12 0,05-0, ,05-0,08 0,05-0,08 0,05-0,10 0,05-0, Slotting - - 0,04-0,10 0,04-0, ,05-0,07 0,05-0,07 0,05-0,08 0,05-0, ,05-0, ,05-0,08 0,05-0,08 0,05-0,10 0,05-0, Slotting ,05-0, ,05-0,07 0,05-0,07 0,05-0,08 0,05-0, ,05-0,13 0,05-0, ,05-0,08 0,05-0,08 0,05-0,10 0,05-0, Slotting - - 0,04-0,10 0,04-0, ,05-0,07 0,05-0,07 0,05-0,08 0,05-0, ,05-0,15 0,05-0,14 0,05-0,13-0,05-0,15 0,05-0,15 0,05-0, Slotting 0,05-0,12 0,05-0,11 0,05-0,11-0,05-0,12 0,05-0,12 0,05-0, ,05-0,15 0,05-0, ,05-0,15 0,05-0,15 0,05-0, Slotting 0,05-0,12 0,05-0, ,05-0,12 0,05-0,12 0,05-0, ,05-0,13 0,05-0, ,05-0,15 0,05-0,15 0,05-0, Slotting 0,05-0,11 0,05-0, ,05-0,12 0,05-0,12 0,05-0, ,15-0,18 0,15-0, Slotting ,15-0,18 0,15-0, Slotting ,15-0,18 0,15-0,18 0,15-0, Slotting Note: HTA = High Temperature Alloys Note: Above feed rates are calculated on centreline. Speed recommendations can be found on page

5 5230VS09 Speed v c 5230VS Series Coolant Recommendation Recommended CVD X Grade -- Speed min. - max. PVD Standard CVD Standard ISO P M K Materials Unalloyed Alloyed Stainless PH Stainless Cast Iron N Aluminium & Alloys Rm and Hardness MP91M <600 N/mm <180 HBN <950 N/mm <280 HBN N/mm HBN N/mm HBN N/mm HBN Refractory P.H Grey GG-Ft Spheroidal-Ductile GGG-FGS Malleable GTS - MN/MP < 16% Si 116 HBN > 16% Si 92 HBN S High Temperature Alloys H Hard Materials Hard >415 HBN > 400 HBN 183

6 5230VS12 Chevron Long Edge Milling (Porcupine) d 1 H D Shell Mill Fixation a p max Slotting Product Dimensions (mm) Spares EDP Item Description D L/H l1 d1 ap max ap max No. of Slotting* No. of 5230VS12 Shell Mill Fixation VS12-A063Z4R F4011T T20 3, VS12-A063Z4R F4011T T20 3, VS12-A080Z5R F4011T T20 3, VS12-A080Z5R F4011T T20 3, VS12-A100Z6R F4011T T20 3, VS12-A100Z6R F4011T T20 3,10 * Note: Please do not surpass the recommended max. ap for slotting. EDP EDP Screw Tightening Nm Shell Mills are supplied with inserts screws, coolant control screws, steel coolant plug, nord-lock washer and mounting screw. 5230VS12 Spare Parts Screwdriver Coolant Plug Screw EDP Screw Qty. EDP EDP 5230VS12-A063Z4R SB VS12-A063Z4R SB VS12-A080Z5R SB F3006T T9 5230VS12-A080Z5R SB VS12-A100Z6R SB VS12-A100Z6R SB-3234 Coolant Plug tightening Nm VS12 Torque Values and Spare Parts 5230VS12-A063Z4R VS12-A063Z4R VS12-A080Z5R VS12-A080Z5R VS12-A100Z6R VS12-A100Z6R133 Mounting Bolt EDP EDP Normal Condition NLW NLW-12SP NLW-16SP M ISO x 30mm SHCS M16-2 ISO x 40mm SHCS M ISO x 50mm SHCS ** Torque values for mounting bolts. Excessive condition is when long reach extensions are required or when cutting parameters are elevated to extreme parameters. EDP 5230VS12 Technical Information (mm) Product Dimensions Item Description Facing Pitch Ramping Angle Helical Hole min. - max. ap max Helical / Linear Max RPM VS12-A063Z4R VS12-A063Z4R VS12-A080Z5R VS12-A080Z5R VS12-A100Z6R VS12-A100Z6R Flat Facing Pitch 184

7 5230VS12 d r SDHT SDHT SDMT12-41 SDMW12 Product Application & Material Dimensions (mm) Roughing Semi-Finishing Finishing l s EDP Item Description Grade Depth of Cut (mm) ap max* or ap max. and ap min. - max. ae max.* ae max. 15% D** d (IC) l r hm min SDHT120412EN ,70 12,70 4,76 1,20 0, SDHT120412EN ,70 12,70 4,76 1,20 0, SDHT120412EN ,70 12,70 4,76 1,20 0, SDHT120412EN ,70 12,70 4,76 1,20 0, SDMT120412EN-41-12,70 12,70 4,76 1,20 0, SDMT120412EN-41-12,70 12,70 4,76 1,20 0, SDMT120412EN-41 MP91M - 12,70 12,70 4,76 1,20 0, SDMW120412TN ,70 12,70 4,76 1,20 0, SDMW120412TN ,70 12,70 4,76 1,20 0, SDMW120412TN MP91M ,70 12,70 4,76 1,20 0,15 Machining Choice: 1 Choice 2 nd Choice 3 rd * Note: Please do not surpass the recommended max. a p for slotting as shown on the steel body page 184. * Note: a p max. for pro ling is only possible when a e < 75% of the Diameter. ** Note: For semi nishing, axial engagement a p for slotting and radial engagement ae for pro ling should be max. 15% of the Diameter. SDHT120412EN-423 to be used in unstable conditions. Note: Feed recommendations can be found on page 186. Speed recommendations can be found on page

8 5230VS VS12 Feeds f z Geometry Grade Operation Unalloyed Alloyed Refractory PH Gray Iron Spheroidal- Ductile Iron Malleable Iron Aluminium & <16% Si 116 HBN Aluminium & Silicon >16% Si 92 HBN HTA Iron HTA Cobalt HTA Nickel HTA Titanium Hard >415 HBN >400 HBN EN-422 EN-422 EN-423 EN-423 EN-41 EN-41 EN-41 TN TN TN MP91M MP91M Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max. Min. - Max ,05-0,15 0,05-0, ,05-0,10 0,05-0,10 0,05-0,11 0,05-0, Slotting - - 0,05-0,12 0,05-0, ,05-0,09 0,05-0,09 0,05-0,09 0,05-0, ,05-0,15 0,05-0, ,05-0,10 0,05-0,10 0,05-0,11 0,05-0, Slotting - - 0,05-0,12 0,05-0, ,05-0,09 0,05-0,09 0,05-0,09 0,05-0, ,05-0, ,05-0,10 0,05-0,10 0,05-0,11 0,05-0, Slotting ,05-0, ,05-0,09 0,05-0,09 0,05-0,09 0,05-0, ,05-0,15 0,05-0, ,05-0,10 0,05-0,10 0,05-0,11 0,05-0, Slotting - - 0,05-0,12 0,05-0, ,05-0,09 0,05-0,09 0,05-0,09 0,05-0, ,05-0,17 0,05-0,16 0,05-0,15-0,05-0,17 0,05-0,17 0,05-0, Slotting 0,05-0,14 0,05-0,13 0,05-0,12-0,05-0,14 0,05-0,14 0,05-0, ,05-0,17 0,05-0, ,05-0,17 0,05-0,17 0,05-0, Slotting 0,05-0,14 0,05-0, ,05-0,14 0,05-0,14 0,05-0, ,05-0,17 0,05-0, ,05-0,17 0,05-0,17 0,05-0, Slotting 0,05-0,14 0,05-0, ,05-0,14 0,05-0,14 0,05-0, ,15-0,20 0,15-0, Slotting ,15-0,20 0,15-0, Slotting ,15-0,20 0,15-0,20 0,15-0, Slotting Note: HTA = High Temperature Alloys Note: Above feed rates are calculated on centreline. Speed recommendations can be found on page

9 5230VS12 Speed v c 5230VS Series Coolant Recommendation Recommended CVD X Grade -- Speed min. - max. PVD Standard CVD Standard ISO P M K Materials Unalloyed Alloyed Stainless PH Stainless Cast Iron N Aluminium & Alloys Rm and Hardness MP91M <600 N/mm <180 HBN <950 N/mm <280 HBN N/mm HBN N/mm HBN N/mm HBN Refractory P.H Grey GG-Ft Spheroidal-Ductile GGG-FGS Malleable GTS - MN/MP < 16% Si 116 HBN > 16% Si 92 HBN S High Temperature Alloys H Hard Materials Hard >415 HBN > 400 HBN 187

10 5230VS Series Technical Information Calculation of the average chip thickness in relation with the ae e is less than 50% of dia. Formula: Programme Feed Rate (f z f z = h m x d a e h m = Average chip thickness a e = Radial engagement f z = Feed per tooth d = diameter Formula: Average Chip Thickness (h m h m = f z x a e d h m Correction Coefficient Chart Ø 50mm Ø 63mm Ø 80mm Ø 100mm Coefficient Coefficient Coefficient Coefficient a e % a e (mm) a Factor e % a e (mm) a Factor e % a e (mm) a Factor e % a e (mm) Factor 5 2,50 2,30 5 3,15 2,30 5 4,00 2,30 5 5,00 2, ,00 1, ,30 1, ,00 1, ,00 1, ,5 1, ,45 1, ,00 1, ,00 1, ,00 1, ,60 1, ,00 1, ,00 1, ,50 1, ,75 1, ,00 1, ,00 1, ,50 1, ,05 1, ,00 1, ,00 1, ,00-50,00 1, ,50-63,00 1, ,00-80,00 1, ,00-100,00 1,00 Example: A 50mm diameter cutter using 5,00mm radial engagement (a e) = 10% of the cutter diameter. At 10%, your coefficient is 1,66 (see above table); therefore you must multiply your feed rate by 1,66 for correcting the feed for profiling. The chart above shows the multiplication factor for the feed rate based on the percentage of the radial engagement of the cutter diameter. Wiper pockets are identified with a W engraved on the face of the body. The 5230VS cutter series is designed with wiper pockets which provide a much better face surface finish. The non-wiper pockets generate the 90 corner. The same inserts can be utilised in all pockets. 0.6 Pockets setting difference between wiper and nonwiper inserts. Note: The true cutter diameter is measured at the non-wiper pockets. 0,15 0,13 Non wiper pocket positions are set back & square to axis to give a true 90 degree approach. Wiper pocket positions are in front and angled to allow facing. Diameter (mm) No. of Wiper

11 5230VS Series Technical Information 5230VS09 and VS12 Fitting Instructions for Shell Mill s NOTE: All Shell Mill 5230VS09 and VS12 Chevron Porcupine s are supplied assembled with mounting bolt, nord lock washer and steel coolant plug. Please follow the instructions below to disassemble the cutter, attach the cutter to a shell mill adapter and reassemble coolant plug. It is very important to use the proper torque when reassembling the cutter with the mounting bolt, nord lock washer and coolant plug. Example of cutter: 5230VS12-A063Z4R94 assembly COOLANT PLUG SB-3230 NORD LOCK WASHER NLW-.375 CUTTER BODY 5230VS12-A063Z4R94 Close Serrations Open Serrations MOUNTING SCREW M ISO 30MM SHCS REFIT COOLANT PLUG ENSURING NORD LOCK WASHER IS PRESENT AND ASSEMBLE AS THIS PICTURE WITH GREASE. 1. Remove coolant plug. (Note: Ensure the nord lock washer is retained to the bottom of the coolant plug.) 2. Fit the cutter body to the shell mill adapter and secure using the mounting bolt supplied with the cutter. Note: The mounting bolt must be properly torqued to the speci ed torque setting shown in the above chart in (page 190) Detail Re t coolant plug ensuring nord lock washer is present and in the proper location on the bottom of the coolant plug. A small amount of grease can be used to hold the nord lock washer in place. 4. Tighten coolant plug with speci ed torque setting shown in the above chart in (page 190) Detail Note: If axial depth of cut (a p) is less then maximum a p of the cutter, then F3006T coolant control screws supplied separately can be used to block coolant holes forcing more coolant to the front of the cutter. If these screws are used, please secure with loctite or similar product. 189

12 5230VS Technical Information Torque values for mounting bolts Excessive condition is when long reach extensions are required or when cutting parameters are elevated to extreme parameters. 5230VS09 Detail 1 Detail VS09-A050Z4R VS09-A050Z4R80 Mounting Bolt M ISO x 30mm SHCS Normal Condition Condition Coolant Plug SB-3413 SB-3621 Coolant Plug tightening VS12 Detail 1 Detail VS12-A063Z4R VS12-A063Z4R VS12-A080Z5R VS12-A080Z5R VS12-A100Z6R VS12-A100Z6R133 Mounting Bolt M ISO x 30mm SHCS M16-2 ISO x 40mm SHCS M ISO x 50mm SHCS Normal Condition Condition Coolant Plug SB-3229 SB-3230 SB-3231 SB-3232 SB-3233 SB-3234 Coolant Plug tightening