The new force in machining.

Transcription

1 Product handbook Milling _ SILVER, BLACK, STRONG The new force in machining.

2 Yesterday, it was machining. Today, it s tigering. Cutting tool materials with the Tiger tec technology brand are setting the standard in machining again and again, in terms of productivity and process stability. With the new cutting tool material, the engineers at Walter have moved another great step closer to the ideal cutting tool material. is ideal for dry and wet machining of steel and cast iron materials, and is at home in important key sectors: the automotive industry and rail vehicle manufacturing, power engineering, the aerospace industry, mechanical engineering and in mold and die making.

3 CONTENTS Milling 2 2 The new technology 6 Applications and examples 12 Application chart 14 Extract from the milling cutter range 16 Walter Select milling cutters 34 Technical information 34 Cutting data for milling 38 Feed rate specification 54 Application-specific data 68 Description of indexable insert geometry 76 Calculation Formula 78 Problem solving

4 The new technology New Tiger, new benchmark: Up to 100 % increase in output Extremely stable cutting edges for high level of process reliability Extremely smooth rake face for excellent wear resistance Silver colored flank face for extremely easy wear detection during use 2

5 Unique throughout the world With its globally unique CVD coating technology, the cutting tool material is forging ahead into new dimensions. In day-to-day manufacturing, this means that increases in output of up to 100 % are possible in machining. Other features of : Enormous toughness and minimal formation of hairline cracks thanks to optimum residual strength Greatly reduced tribochemical wear thanks to perfect, smooth rake faces Not susceptible to thermal stress variations during wet and dry machining Completely new CVD coating technology: Combines wear resistance and toughness For steel and cast iron workpieces Optimum friction behavior -Al 2 O 3 MT-Ti(C, N) Substrate Greater resistance to flank face wear Excellent hardness to toughness ratio 3

6 The new technology High level of wear resistance A close-up view of the cutting edges shows it clearly: the new cutting tool material can easily handle even the most difficult machining conditions thanks to its new, revolutionary coating. Hairline cracks, such as those that occur at high cutting speeds, with interrupted cuts and difficult cutting conditions in particular, are decisively reduced with indexable inserts. In the example shown, heat treatable steel 4140 was milled twice, with the existing insert and with the new. With the indexable insert, the high level of wear resistance, the toughness and resistance to temperature reduce negative hairline crack formations and chipping, and therefore costly reductions in service life. Existing 4

7 Outstanding properties PRODUCT PROPERTIES: Performance increase of up to 100 % Thanks to excellent wear behavior combined with extreme toughness Excellent cutting and chip evacuation behavior Thanks to extremely smooth rake faces Resistant to deformation and oxidation wear Thanks to the new type of aluminum oxide coating Benefits for you: Low production costs Higher cutting speeds thanks to heat-resistant coating High level of process reliability High level of toughness thanks to technology Improved chip flow thanks to extremely smooth rake faces Low cutting material costs Excellent wear detection thanks to indicator coating Unused cutting edges not wasted High level of resistance to flank face wear Thanks to fine-grained, columnar, average temperature titanium carbonitride New dimension in the toughness to wear resistance ratio Thanks to the new type of coating technology 5

8 Applications and examples THE APPLICATION With the new technology, there is also completely new surface treatment in addition to the special coating combination. Due to the optimal residual stresses, the toughness of the wear-resistant cutting tool material increases exponentially. It is this combination of a high level of wear resistance and toughness that gives superior machining performance. Temperature resistance CVD -Al 2 O 3 Tiger tec PVD-Al 2 O 3 PVD Toughness WALTER GRADE DESIGNATION W K P 35 S Application range Primary application ISO P Walter Primary application ISO K 6

9 Material: steel (ISO P) Temperature resistance WKP 25 WKP 35 S WSP 45 Toughness Material: CAST IRON (ISO K) Temperature resistance WAK 15 WKK 25 WKP 25 WKP 35 S Toughness WKP 35 S Primary application: all steel materials at medium to high cutting speeds and medium to high feeds per tooth. For unfavorable conditions, e.g. wet machining, fluctuating material removal or long projection length. Primary application: spheroidal graphite cast iron or ADI materials at low to medium cutting speeds and medium to high feeds per tooth. For unfavorable conditions, e.g. wet machining, fluctuating material removal or aggressive interrupted cuts. 7

10 Example 1: Machine frame (shoulder milling) Workpiece material: St37 (1.0037), ISO P (BS879M39, Structural Steel) Tool: F4042 / Z6 / dia inch Indexable insert: ADMT160608R-F56 Cutting tool material: WKP35S Cutting data: Competitor Cutting speed v c 1300 SFM 1300 SFM Feed per tooth f z IPT IPT Feed rate v f 95 inch/min 95 inch/min DOC a p inch inch WOC a e 2.36 inch 2.36 inch with coolant with coolant Tool life quantity 1 inner surface 2 inner surfaces Benefits for you: High level of process stability despite unstable weld design; holes and weld seams are also milled in some areas Lower tool costs Comparison in tool life of inner surfaces [pieces] Competition %

11 Example 2: Guide tracks (face milling) Workpiece material: St52-2 (1.0570), ISO P (Structural Steel) Tool: F4080 / Z8 / dia inch Indexable insert: ODHT0605ZZN-F57 Cutting tool material: WKP35S Cutting data: Existing Cutting speed v c 775 SFM 928 SFM Feed per tooth f z IPT IPT Feed rate v f 62 inch/min 78 inch/min DOC a p inch inch WOC a e 3.94 inch 3.94 inch with coolant with coolant Tool life [ft] Benefits for you: Reduced tool costs thanks to doubled service life Machine capacity increased thanks to 26 % higher feed rate Feed rate comparison [in/min] Existing + 26 %

12 Example 3: Form insert (pocket milling) Workpiece material: 40CrMnMo7 (1.2311), ISO P (P20 Steel) Tensile strength: 38 HRc Tool: F4042 / Z6 / dia inch Indexable insert: ADMT160608R-F56 Cutting tool material: WKP35S Cutting data: Existing Cutting speed v c 345 SFM 345 SFM Feed per tooth f z IPT IPT Feed rate v f 38 inch/min 38 inch/min DOC a p inch inch WOC a e inch inch with coolant with coolant Tool life [ft] Benefits for you: A complete component can be reliably machined Lower tool costs Tool life comparison [ft] Existing + 36 %

13 Example 4: Brake caliper (circular face milling) Workpiece material: GGG50 (0.7050), ISO K (Nodular Iron) Tool: F4042R / Z7 / dia inch Indexable insert: ADMT10T308R-F56 Cutting tool material: WKP35S Cutting data: Competitor Cutting speed v c 524 SFM 524 SFM Feed per tooth f z IPT IPT Feed rate v f 60 inch/min 60 inch/min DOC a p inch inch WOC a e 1.00 inch 1.00 inch without coolant without coolant Tool life quantity [pieces] Benefits for you: Reduction in CPP (cost per part) Low tool costs thanks to longer tool life High level of process reliability Tool life quantity comparison [pieces] Competition + 75 %

14 Application chart Workpiece material group P M K N S H Walter grade designation Standard designation Steel Stainless steel Cast iron Non-ferrous metals Materials with difficult cutting properties Hard materials WKP 35 S HC P 35 HC K 35 WKP 25 HC P 25 HC K 25 WAK 15 HC K 15 HC S 45 WSP 45 HC P 45 HC M 45 WKK 25 HC K 25 HC = Coated carbide Primary application 12

15 Application range Coating process Coating composition Indexable insert example CVD TiCN + Al 2 O 3 (+TiCN) CVD TiCN + Al 2 O 3 (+TiN) CVD TiCN + Al 2 O 3 (+TiN) PVD TiAlN + Al 2 O 3 (ZrCN) PVD TiAlN + Al 2 O 3 (ZrCN) 13

16 Extract from the milling cutter range Trimming: F 4238 Slot milling: F 4042R Shoulder milling: F 4042 Pocket milling: F 4042 Circular interpolation milling: F 4081 Plunging: F 4030 Slot milling: F

17 Face milling: F 4033 Copy milling: F 4030 Face milling: F 4045 Shoulder milling: F

18 Walter Select milling cutters Face milling Machining Lead angle κ 45 Face mill F 4033 Xtra tec Dia. range Ordering information* F. page 166 P Steel K Cast iron Basic shape of indexable insert Indexable insert types SN. X SN. X Max. cut depths Number of cutting edges per indexable insert 8 * G. = 2007 General Catalog North American Version E. = 2009 Catalog supplement F. = 2010 Innovation brochure 16

19 F 4047 F 4048 F 4045 Xtra tec Xtra tec Xtra tec E. page 212 E. page 214 F. Page 1176 SN. X SN. X XNHF XNHF Primary application C Additional application 17

20 Walter Select milling cutters Face milling Machining Lead angle κ 43 Face mill F 4080 Xtra tec Dia. range Ordering information* F. Page 178, G. page 518 P Steel K Cast iron Basic shape of indexable insert Indexable insert types OD OD Max. cut depths / / Number of cutting edges per indexable insert 8 * G. = 2007 General Catalog North American Version E. = 2009 Catalog supplement F. = 2010 Innovation brochure 18

21 F 2330 F 4030 Xtra tec G. page 510 F. Page 174 CC CC CC CC P P P CC plication Primary ap C Additional application Tiger tec Silver 19

22 Walter Select milling cutters Face milling Machining Roughing s Finish milling s Shoulder milling Shoulder milling (finishing) Plunging Circular interpolation milling Pocket milling Lead angle κ 45 / 75 / 88 Face mill F 2010 Dia. range Ordering information* G. page 468, 472, 476 P Steel K Cast iron Basic shape of indexable insert Indexable insert types SN. X SN. X Max. cut depths Number of cutting edges per indexable insert 8 * G. = 2007 General Catalog North American Version E. = 2009 Catalog supplement F. = 2010 Innovation brochure 20

23 s s s s s s s s s s s s s s s s s / 45 F G. page 484 G. page 480 G. page 464 G. page 466 G. page 486 LNGX AD AD P R25 P R25 OD RO. X / Primary application C Additional application 21

24 Walter Select milling cutters Shoulder milling Machining Lead angle κ 90 Shoulder milling cutter F 4041 Xtra tec Dia. range Ordering information* G. page 526 P Steel K Cast iron Basic shape of indexable insert Indexable insert types LNGX Max. cut depths Number of cutting edges per indexable insert 4 * G. = 2007 General Catalog North American Version E. = 2009 Catalog supplement F. = 2010 Innovation brochure 22

25 90 90 F 4042R F 4042 Xtra tec Xtra tec E. page 220 G. page AD. T 10T3.. AD. T AD. T AD. T AD. T Primary application C Additional application 23

26 Walter Select milling cutters Shoulder milling Machining Lead angle κ Shoulder milling cutter F 4038 F 4138 Xtra tec Xtra tec Dia. range Ordering information* G. page 558 G. page 560 P Steel K Cast iron Basic shape of indexable insert Indexable insert types AD. T AD. T Max. cut depths Number of cutting edges per indexable insert 2 2 * G. = 2007 General Catalog North American Version E. = 2009 Catalog supplement F. = 2010 Innovation brochure 24

27 90 90 F 4238 F 4338 Xtra tec Xtra tec G. page 562 F. Page 179 AD. T AD. T Primary application C Additional application 25

28 Walter Select milling cutters Slot milling Machining Lead angle κ 90 Slot mill F 4053 Xtra tec Dia. range Ordering information* E. page 224 P Steel K Cast iron Basic shape of indexable insert Indexable insert types LN.X Max. cutting width across teeth Number of cutting edges per indexable insert * G. = 2007 General Catalog North American Version E. = 2009 Catalog supplement F. = 2010 Innovation brochure 26

29 90 90 F 4153 F 4253 Xtra tec Xtra tec E. page 226 E. page 228 LN LN LN LN LN LN LN Primary application C Additional application 27

30 Walter Select milling cutters Copy milling Machining Copy mill F 2334 Dia. range Ordering information* G. page 584 P Steel K Cast iron Basic shape of indexable insert Indexable insert types RO. X.. Max. cut depths Number of cutting edges per indexable insert 4 8 * G. = 2007 General Catalog North American Version E. = 2009 Catalog supplement F. = 2010 Innovation brochure 28

31 Circular interpolation milling Machining Lead angle κ 45 / 90 Circular interpolation mill F 4081 Xtra tec Dia. range [mm] Ordering information* F. Page 177 P Steel K Cast iron Basic shape of indexable insert Indexable insert types OD OD Max. cut depths Number of cutting edges per indexable insert 2 4 Primary application C Additional application 29

32 Walter Select milling cutters Circular interpolation milling Machining 43 Lead angle κ F 4080 Circular interpolation mill Xtra tec Dia. range Ordering information* G. page 518 P Steel CC K Cast iron CC Basic shape of indexable insert Indexable insert types Max. cut depths OD OD / / Number of cutting edges per indexable insert * G. = 2007 General Catalog North American Version E. = 2009 Catalog supplement F. = 2010 Innovation brochure

33 F 2330 F 4030 Xtra tec G. page 510 F. Page 174 CC CC CC CC P P P CC plication Primary ap C Additional application Tiger tec Silver 31

34 Walter Select milling cutters Circular interpolation milling Machining Lead angle κ Circular interpolation mill F 2334 Dia. range Ordering information* G. page 584 P Steel CC K Cast iron CC Basic shape of indexable insert Indexable insert types Max. cut depths RO. X Number of cutting edges per indexable insert * G. = 2007 General Catalog North American Version E. = 2009 Catalog supplement F. = 2010 Innovation brochure

35 90 90 F 4042R F 4042 Xtra tec Xtra tec E. page 220 G. page AD. T 10T3.. AD. T AD. T AD. T AD. T Primary application C Additional application 33

36 Technical Information Cutting data for milling Material group P K Workpiece material approx % C annealed 125 approx % C annealed 190 Unalloyed steel 1 approx % C heat treated 250 approx % C annealed 270 approx % C heat treated 300 annealed 180 heat treated 275 Low-alloy steel 1 heat treated 300 heat treated 350 High-alloyed steel and annealed 200 high-alloyed tool steel 1 hardened and tempered 325 Stainless steel 1 ferritic / martensitic, annealed 200 martensitic, heat treated 240 Grey cast iron Grey cast iron with spheroidal graphite Malleable cast iron Brinell hardness HB pearlitic/ferritic 180 pearlitic (martensitic) 260 ferritic 160 pearlitic 250 ferritic 130 pearlitic

37 Roughing with surface/ shoulder milling cutters Roughing with helical cutters Roughing with side and face mills Machining group 2 1/1 1/2 WKP 35 S WKP 35 S WKP 35 S a e / D C 3 a e / D C 3 a e / D C 1/5 1/1 1/2 1/5 central 1/5 1/ and cast steel 2 The arrangement of the machining group can be found on page 760 of the 2007 General Catalog North American Version 3 a e / D C = 1/10, v C = 10 % higher than 1/5 35

38 Technical Information Cutting data for milling Material group P K Workpiece material approx % C annealed 125 approx % C annealed 190 Unalloyed steel 1 approx % C heat treated 250 approx % C annealed 270 approx % C heat treated 300 annealed 180 heat treated 275 Low-alloy steel 1 heat treated 300 heat treated 350 High-alloyed steel and annealed 200 high-alloyed tool steel 1 hardened and tempered 325 Stainless steel 1 ferritic / martensitic, annealed 200 martensitic, heat treated 240 Grey cast iron Grey cast iron with spheroidal graphite Malleable cast iron Brinell hardness HB pearlitic/ferritic 180 pearlitic (martensitic) 260 ferritic 160 pearlitic 250 ferritic 130 pearlitic

39 Roughing with copy milling cutters Circular interpolation milling Machining group 2 WKP 35 S WKP 35 S a e / D C 3 a e / D C 1/1 1/5 1/10 1/1 1/ and cast steel 2 The arrangement of the machining group can be found on page 760 of the 2007 General Catalog North American Version 3 a e / D C = 1/10, v C = 10 % higher than 1/5 37

40 Technical Information Determining the feed Cutter types F 2010 / F 2330 Face milling Feed per tooth f zo for a e = D c a p = a p max = L c D c a p max Lead angle κ 0 15 f = zo Tool dia. or dia. range Max. depths of cut a = L p max c a p max = a p max = a p max = Unalloyed steel* P Low-alloyed steel* High-alloyed steel and tool steel* Stainless steel*, martensitic Grey cast iron K Cast iron with spheroidal graphite Malleable cast iron Indexable insert types P R 10 P R 14 P R 25 Correction factor Ka e For the feed per tooth dependent on the ratio cut width a e to cutter diameter D c Correction factor Ka p For the feed per tooth dependent on the depth of cut a p Correction factor K Dc f z = f zo Ka e Ka p K L a / D e c = 1/1 1/ / / /20 1/50 a p = <(L : D c) <(L : D c) <(L : D c) * and cast steel 38

41 Face mill: F 2010, F 2330, F4030 F 2330 Plunging F 4030 Face milling F 4030 Plunging Xtra tec Xtra tec f zo = f zo = f zo = a e max = a e max = a e max = a pmax = a emax = P P R 10 P P R 14 P P R 25 P R 14 P R

42 Technical Information Determining the feed Cutter types F 2010 / F 4080 Feed per tooth f zo for a e = D c a p = a p max = L c D c a p max Xtra tec Lead angle κ 43 f = zo Tool dia. or dia. range Max. depths of cut a = L p max c / / Unalloyed steel* P Low-alloyed steel* High-alloyed steel and tool steel* Stainless steel,* martensitic Grey cast iron K Cast iron with spheroidal graphite Malleable cast iron Indexable insert types OD OD Correction factor Ka e For the feed per tooth dependent on the ratio cut width a e to cutting diameter D c Correction factor Ka p For the feed per tooth dependent on the depth of cut a p f z = f zo Ka e Ka p K a / D e c = 1/1 1/ / / / /50 a p = a p max = L c * and cast steel 40

43 Face mill: F 2010, F 4080, F 4081, F 4033, F 4045 F 4081 F 2010 / F 4033 F 4045 Xtra tec Xtra tec Xtra tec f zo = [mm] f zo = f zo = / / OD with corner radius OD with corner radius SN. X SN. X SN. X 1205 ANN SN. X 1606 XNHF 0705 XNHF

44 Technical Information Determining the feed Cutter types F 2010 / F 4047 F 2010 / F 4048 Feed per tooth f zo for a e = D c a p = a p max = L c D c a p max Xtra tec Xtra tec Lead angle κ f = zo f = zo Tool dia. or dia. range Max. depths of cut a = L p max c Unalloyed steel* P Low-alloyed steel* High-alloyed steel and tool steel* Stainless steel,* martensitic Grey cast iron K Cast iron with spheroidal graphite Malleable cast iron Indexable insert types Correction factor Ka e For the feed per tooth dependent on the ratio cut width a e to cutter diameter D c SN. X SN. X SN. X 1205 ENN SN. X SN. X SN. X 1205 ZNN a / D e c = 1/1 1/ / / / /50 f z = f zo Ka e * and cast steel 42

45 Face and shoulder mill: F 2010, F 4047, F 4048, F 4041, F 4042, F 4042R F 2010 / F 4041 F 2010 / F 4042 / F 4042R Xtra tec Xtra tec f = zo f = zo LNGX 1307 AD AD.. 10T3 AD AD AD

46 Technical Information Determining the feed Cutter types F 4038 Feed per tooth f zo for a e = D c a p = a p max = L c D c L c Xtra tec Lead angle κ 90 f = zo Tool dia. or dia. range Max. depths of cut a = L p max c Unalloyed steel* P Low-alloyed steel* High-alloyed steel and tool steel* Stainless steel,* martensitic Grey cast iron K Cast iron with spheroidal graphite Malleable cast iron Indexable insert types AD Correction factor Ka e For the feed per tooth dependent on the ratio cut width a e to cutter diameter D c Correction factor Ka p For the feed per tooth dependent on the depth of cut a p f z = f zo Ka e Ka p K a / D e c = 1/1 1/ / / / / a p = x Dc x Dc x Dc 0.7 a p max = L c * and cast steel 44

47 Shoulder mill: F 4038, F 4138, F 4238, F 4338 F 4138 F 4238 F 4338 Xtra tec Xtra tec Xtra tec f = zo f = zo f = [mm] zo AD AD AD only possible if a p < 0.5 x D 2 C only possible if a e/d C < 1/5 45

48 Technical Information Determining the feed Cutter types F 4053 Feed per tooth f zo for plunging central positioning Xtra tec Lead angle κ 90 f = zo Tool dia. or dia. range Max. depths of cut a = L p max c Unalloyed steel* P Low-alloyed steel* High-alloyed steel and tool steel* Stainless steel,* martensitic Grey cast iron K Cast iron with spheroidal graphite Malleable cast iron Indexable insert types Correction factor Ka e For the feed per tooth dependent on the ratio cut width a e to cutter diameter D c LN. X0702 central 1.0 a / D = e c 1/ / / / / f z = f zo Ka e * and cast steel 46

49 Side and face mills: F 4053, F 4153, F 4253 F 4153 F 4253 Xtra tec Xtra tec f = [mm] zo f = [mm] zo LN LN LN LN LN LN LN Please note: The feed per tooth f z should not exceed 0.24 inch. 47

50 Technical Information Determining the feed of copy mills: F 2010, F 2334 Cutter types F 2010 / F 2334 Feed per tooth f zo for a e = D c a p = a p max = L c D c L c f zo = Tool dia. or dia. range Max. depths of cut a p max = L c P K Unalloyed steel* Low-alloyed steel* High-alloyed steel and tool steel* Stainless steel,* martensitic Grey cast iron Cast iron with spheroidal graphite Malleable cast iron Indexable insert types RO. X 0803 RO. X 10T3 RO. X 1204 RO. X 1605 RO. X 2006 Correction factor Ka e For the feed per tooth dependent on the ratio cut width a e to cutter diameter D c Correction factor Ka p For the feed per tooth dependent on the depth of cut a p f z = f zo Ka e Ka p K a / D e c = 1/1 1/ / / / / a p = * and cast steel 48

51 Circular interpolation mill: F 4081 Cutter types F 4081 Feed per tooth f zo for a e = D a a p = a p max = L c D a L c Xtra tec Lead angle κ 45 f = [mm] zo Tool dia. or dia. range [mm] Max. depths of cut a = L p max c [mm] 3 4 Unalloyed steel* P Low-alloyed steel* High-alloyed steel and tool steel* Stainless steel,* martensitic Grey cast iron K Cast iron with spheroidal graphite Malleable cast iron Indexable insert types OD OD Correction factor Ka e For the feed per tooth dependent on the ratio cut width a e to cutter diameter D c a / D e c = 1/1 1/ / / / /50 f z = f zo Ka e * and cast steel 49

52 Technical Information Determining the feed Cutter types F 4080 Feed per tooth f zo for a e = D a a p = a p max = L c D a L c Xtra tec Lead angle κ 43 f = [mm] zo Tool dia. or dia. range Max. depths of cut a = L p max c Unalloyed steel* P Low-alloyed steel* High-alloyed steel and tool steel* Stainless steel,* martensitic Grey cast iron K Cast iron with spheroidal graphite Malleable cast iron Indexable insert types OD OD Correction factor Ka e For the feed per tooth dependent on the ratio cut width a e to cutter diameter D c a / D e c = 1/1 1/ / / / /50 f z = f zo Ka e * and cast steel 50

53 Circular interpolation mills: F 4080, F 2330, F 4030 F 2330 F 4030 Xtra tec f = zo f = zo P2633.-R10 P26379 R10 P2633.-R14 P26379 R14 P2633.-R25 P26379 R25 P

54 Technical Information Determining the feed Cutter types F 2334 Feed per tooth f zo for a e = D a a p = a p max = L c D a L c Lead angle κ f = zo Tool dia. or dia. range Max. depths of cut a = L p max c Unalloyed steel* P Low-alloyed steel* High-alloyed steel and tool steel* Stainless steel,* martensitic Grey cast iron K Cast iron with spheroidal graphite Malleable cast iron Indexable insert types RO. X RO. X10T3.. RO. X Correction factor Ka e For the feed per tooth dependent on the ratio cut width a e to cutter diameter D c a / D e c = 1/1 1/ / / / /50 f z = f zo Ka e * and cast steel 52

55 Circular interpolation mills: F 2334, F 4042 F 4042 Xtra tec 90 f = [mm] zo RO. X RO. X AD.. T AD.. T10T3.. AD AD.T AD.T

56 Technical Information Application-specific data Face milling (F 4080 only) Maximum cut depth a p OD OD a p a p ap1 ap2 F 4080 F 4081 f/2 f/2 f f D a D a D0 D0 D a Circular interpolation into solid material Range of diameters for milling of bore in one pass Indexable insert OD OD D 0 min D 0 max f max D 0 min D 0 max f max

57 Octagon cutters F 4080 / F 4081 E Da Inclined plunging Max. feed angle E [ ] D a OD OD D a OD OD VERTICAL plunging Max. plunging depth Tmax OD OD T max T max Da Note: Please use the F 4081 with indexable inserts with corner radii only, e.g. ODHT

58 ap Technical Information Application-specific data Face milling Maximum cut depth a p P R 10 P R10 P R 14 P R14 P R 25 P R25 a p max E D a D a P R 10 P R10 Inclined plunging Maximum feed angle E [ ] P R 14 P R14 P R 25 P R a p max Plunging Maximum milling depth a e [mm] P R 10 P R10 P R 14 P R14 P R 25 P R25 a p max a e max 56

59 High-performance mill F 2330 a p max 2 ap max (f) D a D0 D a Circular interpolation into solid material Range of diameters for milling of a hole in one pass P R 10 P R10* D 0 min D 0 max Indexable insert P R 14 P R14* D 0 min D 0 max P R 25 P R25* D 0 min D 0 max *Special geometry for circular interpolation milling (see Description of geometry, page 68) R rt X kr Programming information r k Indexable insert R r rt k kr X P R P R P R P R Programming the theoretical tool radius rt results in a maximum deviation from the final contour as shown. The minimal difference (only in the corners) is corrected by the subsequent tools during the remaining machining operations. 57

60 Technical Information Application-specific data Face milling Maximum cut depth a p P P a p ap Inclined plunging Max. feed angle E [ ] D a P P D a E plunging Maximum milling depth a e D a P P ae max 58

61 High-performance mill F 4030 a p max 2 a p max (f) D a D0 D a Circular interpolation into solid material Range of diameters for milling of bore in one pass P P D 0 min D 0 max D 0 min D 0 max R rt X kr Programming information r k Indexable insert R r rt k kr X P Programming the theoretical tool radius rt results in a maximum deviation from the final contour as shown. The minimal difference (only in the corners) is corrected by the subsequent tools during the remaining machining operations. 59

62 Technical Information Application-specific data Inclined plunging and circular interpolation milling into solid material Plunging with shoulder mill F 4042 / F 4042R AD a max = 8 in AD.. 10T308 a max = 10 in Mill dia. D C Plunging angle E max [ ] D 0 min D 0 max a 0 Plunging angle E max [ ] D 0 min D 0 max a Inclined plunging and circular interpolation milling into solid material Plunging with shoulder milling cutter F 4042 AD a max = 11 in AD a max = 15 in Mill dia. D C Plunging angle E max [ ] D 0 min D 0 max a 0 Plunging angle E max [ ] D 0 min D 0 max a

63 Shoulder mills F 4042, F 4042R E a 1 Inclined plunging and circular interpolation milling into solid material Plunging with shoulder milling cutter F 4042 AD a max = 16 in a 2 a a 1 max E a 0 Mill dia. D C Plunging angle E max [ ] D 0 min D 0 max a a 0 E L an an L Explanation of letter symbols a 0 amount by which the tool is to be lifted off at the end of ramping before starting the next Ramping operation a n depth of cut a max max. depth of cut of tool E [ ] rampint angle L groove length without radius n Number of rampint operations into inclined surface Groove depth after 2 plunging operations: a 2 = 2 L tan E a 0 Groove depth after plunging: a n = n L tan E (n 1) a 0 Ramping angle: Number of inclined plunging operations: tan E = [a n + (n 1) a 0 ] (n L) n = (a n a 0 ) (L tan E max a 0 ) 61

64 Technical Information Application-specific data Machined hole dia. D 0 Circular face milling Max. axial feed per tool revolution ( thread pitch ) f AD D C Machined hole dia. D 0 Circular face milling Max. axial feed per tool revolution ( thread pitch ) f AD.. 10T308 D C

65 Shoulder mills F 4042, F 4042R (continued) Circular INTERPOLATION MILLING f/2 Max. axial feed per tool revolution ( thread pitch ) f D0 D C f Machined hole dia. D 0 AD D C Machined hole dia. D 0 Circular INTERPOLATION MILLING Max. axial feed per tool revolution ( thread pitch ) f AD D C AD D C

66 Technical Information Application-specific data apmax d Face milling Maximum cut depth a p Insert diameter d d = d = d = d = d = d = d = d = a pmax t R a r f/2 f D a d D 0 D a Circular interpolation into solid material Range of diameters for milling of a hole in one pass Insert diameter d d = d = d = d = D 0 min D 0 max D 0 min D 0 max D 0 min D 0 max D 0 min D 0 max D 0 min D 0 max

67 Round insert cutter F 2334 t R a r f/2 f d D a D0 Circular interpolation into solid material Groove depth on the hole wall t R Axial feed rate Insert diameter d per revolution f d = d = d = d = d = d = d = d = (0.0394) (0.0563) (0.0441) (0.0602) (0.0457) (0.0421) a r max

68 Technical Information Application-specific data a pmax D a d E D a Inclined plunging Maximum feed angle E [ ] Indexable insert diameter d d = d = d = d = d = apmax Tmax d Vertical plunging Maximum plunging depth T max Indexable insert diameter d d = d = d = d = d = T max

69 Round insert cutter F 2334 (continued) vf a pz Ez d D a d=0.787 d=0.630 d=0.591 d=0.472 d=0.394 d=0.276/ d=0.315 d=0.197 UP MILLING OF STEEP SURFACES F 2334: Maximum plunging depth T max

70 Technical Information Description of indexable insert geometry Geometry example Remarks on application area P The easy-cutting one For good machining conditions Low cutting forces Medium feed rates Cut Main cutting edge 10 Workpiece material group P M K N S H Suitable tool families F 2010 F 2330 P The stable one For unfavorable machining conditions Maximum cutting edge stability High feed rates 0 P The universal one For medium machining conditions Universal application for most materials Cutting edge 0 Main cutting edge 10 P The special one For circular interpolation milling Universal application for most materials Trailing edge version Cutting edge 0 Main cutting edge 10 P = Steel M = Stainless steel K = Cast iron N = Non-ferrous metals S = Materials with difficult cutting properties H = Hard materials Primary application C Additional application 68

71 Face mills and circular interpolation mills Geometry example Remarks on application area Cut Main cutting edge Workpiece material group P M K N S H Suitable tool families P The universal one For medium to unfavorable machining conditions Universal application for most materials 20 F 4030 OD.. A27 The stable one For unfavorable machining conditions Maximum cutting edge stability High feed rates 0 F 2010 F 4080 F 4081 A57 The special one For medium machining conditions Predominantly for cast iron machining 0 C D57 The universal one For medium machining conditions Universal application for most materials 10 F57 The easy-cutting one For good machining conditions Low cutting forces Medium feed rates 16 G88 The sharp one For machining aluminum Low cutting forces Sharp cutting edges 20 Primary application C Additional application 69

72 Technical Information Description of indexable insert geometry Geometry example SN. X.. Remarks on application area D27 The special one For machining cast iron materials For sand inclusions or casting skin Maximum process reliability Cut Main cutting edge 10 Workpiece material group P M K N S H C Suitable tool families F 2010 F 4033 F 4047 F 4048 F27 The stable one For unfavorable machining conditions Maximum cutting edge stability High feed rates 16 F57 The universal one For medium machining conditions Universal application for most materials 16 F67 The easy-cutting one For good machining conditions Low cutting forces Medium feed rates 16 K88 The sharp one For machining aluminum Low cutting forces Sharp cutting edges 22 P = Steel M = Stainless steel K = Cast iron N = Non-ferrous metals S = Materials with difficult cutting properties H = Hard materials Primary application C Additional application 70

73 Face and shoulder mills Geometry example XNHF.. Remarks on application area D27 The stable one For unfavorable machining conditions Maximum cutting edge stability High feed rates Cut Main cutting edge 10 Workpiece material group P M K N S H C Suitable tool families F 4045 D57 The universal one For medium machining conditions Universal application 10 C D67 The easy-cutting one For good machining conditions Low cutting forces Medium feed rates 10 C L55 The universal one For medium machining conditions Universal application for most materials 20 F 2010 F 4041 LNGX.. L88 The sharp one For machining aluminum Low cutting forces Sharp cutting edges 28 Primary application C Additional application 71

74 Technical Information Description of indexable insert geometry shoulder mills Geometry example AD. T.. Remarks on application area D51 The quiet one Antivibration geometry For tools with longer projection lengths D56 The stable one For unfavorable machining conditions Maximum cutting edge stability High feed rates Cut Main cutting edge Workpiece material group P M K N S H Suitable tool families F2010 F 4042 F 4042R F 4038 F 4138 F 4238 F 4338 D67 The powerful one High cutting edge stability For machining high-alloy and high-tensile steels and Ni-based alloys High level of accuracy 10 C F56 The universal one For medium machining conditions Universal application for most materials 16 G56 The easy-cutting one For good machining conditions Low cutting forces Medium feed rates 20 G77 The special one For machining titanium materials Low cutting forces High level of accuracy 20 C G88 The sharp one for machining aluminum Low cutting forces Sharp cutting edges 20 72

75 Copy mill Geometry example RO. X.. Remarks on application area A27 The stable one For unfavorable machining conditions Maximum cutting edge stability High feed rates Cut Main cutting edge 0 Workpiece material group P M K N S H Suitable tool families F 2010 F 2334 D57 The universal one For medium machining conditions Universal application for most materials 10 D67 The powerful one High cutting edge stability For machining high-alloy and high-tensile steels and Ni-based alloys, e.g. Inconel High level of accuracy 10 C G77 The special one For machining titanium materials Low cutting forces High level of accuracy 20 C P = Steel M = Stainless steel K = Cast iron N = Non-ferrous metals S = Materials with difficult cutting properties H = Hard materials Primary application C Additional application 73

76 Technical Information Description of side and face mill geometry Geometry example LN. X.. Remarks on application area D57T The stable one For unfavorable machining conditions Maximum cutting edge stability High feed rates Cut Main cutting edge 12 Workpiece material group P M K N S H Suitable tool families F 4053 F57T The universal one For medium machining conditions Universal application for most materials 18 LN. U.. B57T The stable one For unfavorable machining conditions Maximum cutting edge stability High feed rates 6 F 4153 F 4253 F57T The universal one For medium machining conditions Universal application for most materials 16 P = Steel M = Stainless steel K = Cast iron N = Non-ferrous metals S = Materials with difficult cutting properties H = Hard materials Primary application C Additional application 74

77 Workpiece material groups Steel k cw 1.1 * (lbs/in 2 ) m cw * Low-carbon soft steel; low tensile ferritic steel 260, Low-carbon free cutting steel 178, P Normal stuctural steel, low to medium content of carbon (< 0.5% C) Normal, low-alloy steel and steel casting; tempering steel; carbon steel (> 0.5% C); ferritic and martensitic stainless steel Normal tool steel; harder tempering steel; martensitic, stainless steel 247, , , Tool steel featuring difficult cutting properties; hard, high-alloyed steel and steel casting; martensitic, stainless steel 274, High tensile steel with difficult cutting properties; hardened steels of the groups 3 6; martensitic, stainless steel 302, Cast Iron k cw 1.1 * (lbs/in 2 ) m cw * Cast iron of medium hardness, grey cast iron 192, K Low-alloyed cast iron, malleable cast iron, nodular cast iron 211, Cast iron alloy of medium hardness, malleable cast iron, GGG, medium cutting properties 221, High-alloyed cast iron with difficult cutting properties; malleable cast iron, GGG, difficult cutting properties 230,

78 Technical Information Calculation formula Number of Revolutions π Feed per tooth fz = vf Z x n Cutting speed Dc x π x n vc = [ft/min] 12 Metal removal rate Q = ae x ap x vf [in 3 /min] Feed rate Power requirement ae x ap x f z x Z x n x kc [HP] 396,000 n Number of revolutions rpm D C Cutting diameter in a p Cutting depth in a e Width of cut in Z Number of teeth v c Cutting speed ft/min v f Feed rate in/min f z Feed rate per tooth in Q Metal removal rate in 3 /min P mot Power requirement HP h m Average chip thickness in h Machine efficiency ( ) k Approach angle j s Cutter engagement angle k cw 1.1 * Specific cutting force lbs/in 2 related to a chip section of 1 in 2 * m cw k c curve rise * mcw and k cw1.1 see table on page 75 76

79 Chip thickness Engagement angle κ where cutter is positioned centrally or h m f z x a e D c where cutter is positioned eccentrically as an approximation for a e/d c < 30 % Specific cutting force f z φ 2 D c φ s a e φ1 h m φm Vf φ 2 = 90 φ s D c a e φ 1 y = a e D c /2 77

80 Technical Information Problem solving Formation of hairline cracks Flank face wear Feature In relation to the cutting edge, vertical small cracks that can result in chipping along the edge and fractures in the indexable insert. Cause Formation of hairline cracks resulting from stresses caused by changes in temperature Due to an interrupted cut (brief contact time between cutting edge and workpiece, long cooling phase) Use of coolant (thermal shock) Remedy / measure(s) Try working without coolant Use a tougher cutting material Reduce the cutting speed Feature The most frequently occurring type of wear, affecting the flank face. Cause Caused by abrasion between the flank face and workpiece During roughing, this often leads to vibrations and increased capacity requirements. During finishing, it can lead to poor surfaces Remedy / measure(s) Use a wear-resistant cutting material Reduce the cutting speed Increase the feed 78

81 Chips along the edge Plastic deformation Feature Chipping along the edges of small sections of the cutting material in the cutting edge. Cause Mechanical overload leads to small sections of the cutting material in the cutting edge breaking off May be a result of hairline cracks Remedy / measure(s) Select a more stable geometry (longer removal phase) Ensure a stable machining process Use a tougher cutting material Feature Cutting edge deformed in some other, undefined manner. Cause Occurs at high machining temperatures in conjunction with a high mechanical load, because of softening and yielding of the cutting tool material Leads to a sudden and sharp increase in the machining temperature and cutting force, fluctuations in dimensions and poor surfaces on the component, and sometimes fractures in the cutting edge Remedy / measure(s) Use a wear-resistant cutting material Reduce the cutting speed Reduce feed 79