SU MMARY - BROACHING TOOLS

Transcription

1 SU MMAY - BOACHING TOOLS Type SH117 - Holder can be located directly in the turret and m/ c spindle Broaching Chamfering Dimensions DIN Inserts w Toolholder Tool length Tool length l2 Inserts Toolholder l2 D min t Width Tolerance grade 6 C , 6 S , 12 SH S SH C , 3 S , 13 SH S SH C , 4 S , 13 SH S SH C , 2 S , 13 SH S SH C , 1 S , 15 SH S SH C , 6 S , 15 SH S SH C , 5 S , 15 SH S SH P9 17 2, 7 S , 98 SH S SH P9 17 3, 4 S , 98 SH S SH P9 22 4, 1 S , 98 SH S SH P9 30 4, 2 S , 98 SH S SH P9 38 5, 7 S , 97 SH S SH P9 40 6, 8 S , 97 SH S SH JS9 17 2, 7 S , 01 SH S SH JS9 17 3, 4 S , 01 SH S SH JS9 22 4, 1 S , 01 SH S SH JS9 30 4, 2 S , 01 SH S SH JS9 38 5, 7 S , 01 SH S SH JS9 38 8, 5 S , 00 SH S SH JS9 40 6, 8 S , 01 SH S SH

2 Appl icati on Tips: - It is important to use a machine with mechanical spindle lock. - The use of proper coolant is key to a goo surface finish long tool life as well as chip evacuation. - A relief groove or the possibility for a "ramp down" ex it out of the cut is necessary at the end of the broached groove. - Setting of the tool if very important. Double check the component diameter before taking the first pass. - The tool should be set at the 12 o' clock position to ensure that chips fall away from the groove. - Tak e an accurate measurement of the insert and program the dimension into the machine tool parameter. - osition the tool at the start position of the first stroke an d program a stop to perform a visual check to assure a collision free first pass of the tool Mac hini ng ex ampl e: Bore diameter 32 mm, groove width 8 mm: At a radius of 16 mm and with a clearance of 0, 2 mm for safety at the r 0, 2 mm corner radii, the tool has to be set at 15, 292 mm in X- ax is to avoid any collision at the beginning of the process. Calculation of the start position b 1 : c 2 = a 2 + b 2 b 2 = c 2 - a 2 b = c 2 - a 2 b = b = 15, b 1 = b - Clearance distance b 1 = 15, 492-0, 2 = 15, 292 mm equals as a start position at Ø mm Dimensions in mm 34

3 400 N/mm 2 S/SU117 Feed rate mm/ mi n N/NU N/mm 2 N/NU110 In-f eed per stro ke i n mm lb/in 2 S/SU117 Feed rate inc h/mi n lb/in 2 N/NU105 N/NU In-f eed per stro ke i n i nc h 35

4 POGAM MING EX AM PLE Ex ampl e f or bro ac hing o n a TAU B TNA 400 w ith C-Ax is NC - Program N (BOACHING) Sequence Number and Application G97 T M5 constant PM, Tool callout, Spindle Stop M17 G94 L1 = C - ax is ON Feed ate in mm/ min choose Parameter for start Ø M8 M 19 Coolant ON, Spindle Break ON N100 G0 XL1 Z 5 G1 Z -25 F8000 G0 X G0 Z 5 L1 = L N200 Sequence Number for repetition STAT Start position in X and Z in front of part Linear move in Z at feed rate of 8000 mm/ min apid move in X to start Ø i.e. drop down position apid move in Z to start position. As Ø programming is in effect the depth of cut must be doubled (Depth of Cut is 0.08 mm) Sequence Number of repetition END. Q G22 P H45 epetition Cycle with Sequence Number from STAT to END and Number of repetitions Ex ample: - Groove according to table in bore Ø 32 mm - Groove width 8 C11 - Depth of Cut per Strok e 0.08 mm - The Number o f Stro kes resulted out of complete cutting depth from start position to the bottom of the groove divided by depth of cut per strok e - This. alue must then be multiplied by 2 ( because Ø Programming) and Value is programmed as the Number of Strok es in the NC- Programme. Calculation: - Starting Position = Security Distance + Distance from Ø 32 mm to Cutting Edge (see Example on Page 34) equals a segment height of mm + Security Distance of 0.20 mm to a total of mm. - Starting Position = mm (32 - [0.708 x 2] = mm. - The groove depth of 2.90 mm added to the mm = mm. - This is the dimension from the starting position to the bottom of the groove and in order to program this on the Ø, the mm dimension must be mul ti pl ied by 2 which will equal the sum of mm. - When the mm is divided by (2 x 0.08 mm) = 0.16 mm depth per strok e the esult will be 45.1 Stro kes and therefore 45 to tal Stro kes are programmed. The remainder of 0.1 Strokes to achieve the finish dimension must be programmed using the fine correction. Attenti on: Th e true d epth o f c ut f or th e i nsert w ill be 0.08 mm. 36

5 POGAM MING EX AM PLE Ex ampl e f or bro ac hing o n SIEM ENS Co ntro l M ac hines w ith l ockabl e Spi nd le NC - Program N (BOACHING) Sequence Number and Application T M 5 LF Tool callout, Spindle Stop M LF Brak e ON G94 LF 1 = LF M8 LF N100 LF G0 X1 Z 5 LF G1 Z -25 F8000 LF G0 X G0 Z 5 1 = N200 Feed ate in mm/ min choose Parameter for start Ø Coolant ON Sequence Number for repetition STAT Start position in X and Z in front of part Linear move in Z at feed rate of 8000 mm/ min apid move in X to start Ø i.e. drop down position apid move in Z to start position. As Ø programming is in effect the depth of cut must be doubled (Depth of Cut is 0.08 mm) Sequence Number of repetition END...LF epetition Cycle with Sequence Number from STAT to END and Number of repetitions. Ex ample: - Groove according to table in bore Ø 32 mm - Groove width 8 C11 - Depth of Cut per Strok e 0.08 mm - The Number o f Stro kes resulted out of complete cutting depth from start position to the bottom of the groove divided by depth of cut per strok e - This Value must then be multiplied by 2 ( because Ø Programming) and Value is programmed as the Number of Strok es in the NC- Programme. Calculation: - Starting Position = Security Distance + Distance from Ø 32 mm to Cutting Edge (see Example on Page 34) equals a segment height of mm + Security Distance of 0.20 mm to a total of mm. - Starting Position = mm (32 - [0.708 x 2] = mm. - The groove depth of 2.90 mm added to the mm = mm. - This is the dimension from the starting position to the bottom of the groove and in order to program this on the Ø, the mm dimension must be mul ti pl ied by 2 which will equal the sum of mm. - When the mm is divided by (2 x 0.08 mm) = 0.16 mm depth per strok e the esult will be 45.1 Stro kes and therefore 45 to tal Stro kes are programmed. The remainder of 0.1 Strokes to achieve the finish dimension must be programmed using the fine correction. 37

6 CHOICE OF CABIDE GADES I Carbide G uncoated rades coated Wear resistance Cutting speed Toughness Feed rate TH35 TH35 TH35 TA45 TA45 TA45 TI25 TI25 TI25 TN35 TN35 TN35 MG12 MG12 MG P M K Steel Stainless steel Grey cast iron / Aluminum 38

7 CHOICE OF CABIDE GADES II Carbide G uncoated rades coated Synthetic cutting- tool material Hardened materials H 01 Toughness High temp. alloys S Non ferrous metals MG12 TI25 TA45 Feed rate Wear resistance Cutting speed 10 N 01 39

8 CABIDE GADES UNCOATED GADES MG12 - a universal grade with good wear resistance. Used at low or medium cutting speeds for machining steel, cast iron and non ferrous materials COATED GADES TN35 - a very popular grade TiN coated used to low or medium cutting speeds. Also recommanded for machining stainless steel or exo tic alloyed materials TI25 - a TiCN coated grade with high abrasion resistance. ecommended for machining steel and non ferrous materials at medium cutting speeds TA45 - a TiAlN coated grade. This coating has a very high temperature stability and high hardness. TH35 - new standard grade - ext reme Oxi dation resistance with high hardness and very good coefficient of friction. 40