TECHNICAL INFORMATION

Transcription

1 TECNICAL INFORMATION Feed rates and time calculation It is simple and easy to calculate your speed and feeds using ORN S CT program. We recommend that you calculate the cutting data with this program as it will provide you with the best cutting performance and results. Basic features of the calculations can be found on the follwing pages. CT (ORN Circular Technology) - safe and fast - Your cutting data for groove milling by circular interpolation of internal and external grooves as well as groove milling of linear grooves. System requirements from Windows 95. Available on CD-ROM. BASIC RECOMMENDATIONS Overhang of the milling cutter Select the shortest possible clamping device and milling shank, and control the runout tolerance of the tools. Large cutting widths in combination with long overhangs require specific manufacturing methods such as dividing the cutting width to achieve the best possible cutting result due to reduced cutting forces. Diameter of the milling cutter When using a large diameter cutter, whose relationship is close to the bore diameter, manufacturing cycletime can be reduced, due to the smaller center of rotation and higher feed rates. Many times the rotation of the milling cutter centre will be defined by the parameters of the workpiece and the whole application setup. Clamping torque of the screws We recommend to use a torque screw driver to achieve the indicated torque values per insert and tool type. Additional additives such as copper paste are not permitted. This will have a negative effect and change the clamping forces. All clamping screws are already coated with additives. M d ORN 1

2 TECNICAL INFORMATION Milling direction Most ORN milling tools are right handed, and it is recommended to use them with the climb milling process as this is generally recommend for carbide tools. Milling entry into the workpiece Ramp angle > 45 A simple radial entry of the milling cutter creates a very long contact angle which leads to vibrations which will not disappear for the rest of the milling operation and are visual on the bottom of the groove. It is recommended to enter the groove with a ramp angle of 45 up to 180 to the maximum depth of cut. The calculated cutting data refers to the milling condition when the insert is in the full cut but can be also used for the entry loop. Bore milling and offset milling by helical interpolation ORN milling inserts are manufactured with a round chip breaker. This means that beyond a depth of cut of 2 mm in axial direction the insert gets a negative cutting angle. Milling inserts are limited to a depth of cut of 2 mm when used for helical interpolation. Larger depths of cut can only be produced when choosing special chip breakers. Please contact us in case of any further questions ORN

3 TECNICAL INFORMATION Sinlge edged inserts When entering through a bore off center and without rotating it is possible to generate back chamfers and flats with inserts having a larger cutting diameter than the bore diameter. Single edged cutters have no run out tolerance. Thread milling With ORN thread milling inserts the thread profile is generated in one full cut to the profile depth of the thread. This produces threads with minimal taper especially in high alloyed steels. In blind holes it is recommended to mill from the bottom to the top. Otherwise there is the risk of damaging the tool because of milling into chips at the bottom of the blind hole. A general recommendation for thread milling: The milling cutter diameter should not exceed 70% of the minor diameter of the thread. Otherwise recutting of the profile occurs which could bring the whole thread out of tolerance ORN 3

4 GROOVE MILLING by circular interpolation MILLING OF A LINEAR GROOVE - EXTERNAL s z = h m 2r a r s = n z s z mm/min Cos φ = r2 + [R + r - a r ] 2 - R 2 φ 2r [R + r - a r ] L = ϖ 2r φ mm 360 Length of cut t = A T n z A z min Time for cut (for A T ) A Z = L h м mm 2 Area of chip s' 1 = ϖ 2 (R+r-a r ) mm/min t Feed rate of tool centre A T = ϖ [R 2 -(R-a r ) 2 ] mm 2 Area of groove section s' 2 = s' 1 R - a r mm/min R + r - a r Feed rate of tool tip 4 CT (ORN Circular Technology) - safe and fast - Your cutting data for groove milling by circular interpolation of internal and external grooves as well as groove milling of linear grooves. System requirements from Windows 95. Available on CD-ROM ORN

5 GROOVE MILLING by circular interpolation MILLING OF AN INTERNAL GROOVE Cos [180 - φ ] = r2 + [R + a r - r] 2 - R φ φ 2r [R + a r - r] L = ϖ 2r φ mm 360 A Z = L h m mm 2 Length of cut Area of chip t = A T n z A z min s' 1 = ϖ 2 (R+r-a r ) mm/min t Time for cut (for A T ) Feed rate of tool centre A T = ϖ [R 2 -(R-a r ) 2 ] mm 2 Area of groove section s' 2 = s' 1 R - a r mm/min R + r - a r Feed rate of tool tip Specification ISO Specification Specification ISOSpecification Feed rate s' v f Radius of cutter r r Revolutions n n Radius of workpiece R R Number of teeth z z Feed rate of tool centre s 1 v f 3 Feed/tooth medium thickness of chip s z h m f z h m Feed rate of tool tip s 2 v f2 radial depth of cut a r a e ORN 5

6 TORQUE OF SCREWS Following torques are allowed for screws of inserts. For torque screw drivers please see chapter additional equipment. Type Screw M d Nm Torque lbf-in. Wrench Blade T20P T20PQ DT20PK / DT20PQ T20P T20PQ DT20PK / DT20PQ F.06T15P T15PQ DT15PK F.08T20P T20PQ DT20PK /12/ T20P T20PQ DT20PK / DT20PQ F.06T15P T15PQ DT15PK F.08T20P T20PQ DT20PK / T20P T20PQ DT20PK / DT20PQ ABS 5.12T20P T20PQ DT20PK / DT20PQ ADR C T6W DT6K ADR.02/03... C T8L DT8K ADR.04/05/06... C T8L DT8K B105/BKT T15P T15PQ DT15PK B110/BKT T15P T15PQ DT15PK BKT T20P T20PQ DT20PK / DT20PQ DAM T10P T10PL DT10PK DAM B T8P T8PL DT8PK DAM A/B T8P T8PL DT8PK DAM A/B T8P T8PL DT8PK DAM A/B T8P T8PL DT8PK DAM A/B T10P T10PL DT10PK DAM D...03A/B T10P T10PL DT10PK DAM D...03A/B T10P T10PL DT10PK DAM M...03B T10P T10PL DT10PK DRD 6.075T15P T15PQ DT15PK SK 5.12T20P T20PQ DT20PK / DT20PQ L381.A... 5F.08T20P T20PQ DT20PK L381.D F.08T20P T20PQ DT20PK L381.D T20P T20PQ DT20PK / DT20PQ L381.G T20P T20PQ DT20PK / DT20PQ L381.G F.08T20P T20PQ DT20PK L381.G086/090/ T20P T20PQ DT20PK / DT20PQ L381.G T20P T20PQ DT20PK / DT20PQ L381.N F.08T20P T20PQ DT20PK L381.S T20P T20PQ DT20PK / DT20PQ L381.T... 5F.08T20P T20PQ DT20PK L381.X T20P T20PQ DT20PK / DT20PQ LM275.D P T10PL DT10PK ORN

7 TORQUE OF SCREWS Following torques are allowed for screws of inserts. For torque screw drivers please see chapter additional equipment. Type Screw M d Nm Torque lbf-in. Wrench Blade M T20EP T20PQ DT20PK / DT20PQ M117K P T8PL DT8PK M117K P T8PL DT8PK M117K P T15PQ DT15PK M117.MD P T15PQ DT15PK M117U P T8PL DT8PK M117U T8EP T8PL DT8PK M117P P T8PL DT8PK M117P T8EP T8PL DT8PK M T10P T10PL DT10PK M T8EP T8PL DT8PK M T10EP T10PL DT10PK M T7P T7PL DT7PK M T8P T8PL DT8PK M T8P T8PL DT15PK M T15P T15PQ DT15PK M B/E 4.16T15KP T15PQ DT15PK M T20P T20PQ DT20PK / DT20PQ M B/E 5.15T20KP T20PQ DT20PK / DT20PQ M T20P T20PQ DT20PK / DT20PQ M B/E 5.13T20KP T20PQ DT20PK / DT20PQ M D T20P T20PQ DT20PK / DT20PQ M T20P T20PQ DT20PK / DT20PQ M T25P T25PQ DT20PQ MDR C T6W DT6K MDR.02/03... C T8L DT8K MDR.04/05/06... C T8L DT8K MDR.08/09/10... C T15Q DT15K R381.X T20P T20PQ DT20PK / DT20PQ R381.X F.08T20P T20PQ DT20PK / DT20PQ RM275.D P T10PL DT10PK RM275.T T10P T10PL DT10PK SM T20P T20PQ DT20PK / DT20PQ Z T20P T20PQ DT20PK / DT20PQ Z T20P T20PQ DT20PK / DT20PQ Z T20P T20PQ DT20PK / DT20PQ ORN 7

8 Available METRIC size carbide and tungsten alloy shanks - Summary Dimensions in mm Part number Inserts (inch and metric) Use Page l 1 d g6 l 2 d 1 Type t max Ds M B M B M B/E M B/E M B/E M B/E/A M B/E/A M B/E/A A A59 108/ / /11.7 A3 - A M A D3; E2 108/ / / M A E M B/E/A M /B/E/A 108/ / /11.7 D M306.ST10.01A 108/ / /11.7 A M B/E/A M B/E/A M B/E/A 111/308/ / /15.7 A25-A M A 111/308/ / /15.7 D11; E M B/E/A M B/E/A M308.ST10.01A M308.ST13.01A M B/E/A M B/E/A M B/E/A 111/ / /15.7 D11 111/ / /15.7 A27 311/ / A43-A M B/E G M B/E/A M B/E/A M B/E/A M B/E/A M B/E/A M B/E/A M311.ST10.01A 311/ / A43-A44 311/ D M311.ST13.01A 311/ A M311.ST16.01A M B/E/A M B/E/A 313/ / A65-A M B/E G M B/E/A M B/E/A M B/E/A M A M A/B/E M A/B/E M A/B/E 313/ / A65-A66 313/ D35 Dimensions in mm ORN

9 Available METRIC size carbide and tungsten alloy shanks - Summary Dimensions in mm Part number Inserts (inch and metric) Use Page l 1 d g6 l 2 d 1 Type t max Ds M313.ST10.01A M313.ST13.01A M313.ST16.01A M A M A M B/E/A M B/E/A M B/E/A M B/E/A M B/E/A M B/E/A 313/ A67 328/ A95 325/328/ /6.4/ /27.7 A93 - A M B/E G SM B/E SM B/E SM B/E D SM B/E M328.ST13.01A M328.ST20.01A 328/ A M A M A M A M A A M A M A M A M A A M332.ST A A M B/A M B/A/E / A127 - A128 Dimensions in mm ORN 9

10 Available INC size carbide and tungsten alloy shanks - Summary Diemsnions in inch Part number Inserts (inch and metric) Use Page l 1 d g6 l 2 d 1 Type t max Ds MU B 108/ / / MU B 108/ / /.461 A2; D MU B 108/ / / MU B 108/ / / MU B 111/ / / MU B 111/ / /.618 A24; D MU B 111/ / / MU B 111/ / / MU B 311/ MU B 311/ A MU B 311/ MU B G MU B 311/ MU B 311/ A MU B 311/ MU B D MU B MU A 313/ MU B 313/ A MU B 313/ MU B G MU B 313/ MU B 313/ A MU B 313/ MU B 313/ D MU B 313/ MU A 313/ MU B 328/ MU B 328/ MU B 328/ A MU B 328/ MU B 328/ MU B 328/ MU B G SMU B SMU B SMU B D SMU B Dimensions in inch ORN

11 COICE OF CARBIDE GRADES Synthetic cutting-tool material PD10 PD20 Wear resistance Cutting speed Toughness Feed rate CB10 CB20 01 N Non ferrous metals igh temp. alloys ardened materials S Carbide Grades Main selection supplementary grades Carbide Grades uncoated coated MG12 TI25 MG12 TN35 T35 Wear resistance Cutting speed Toughness Feed rate P 35 T35 TN35 TI25 54 TF45 MG12 TN35 TI25 54 TF45 MG12 TF46 Steel Stainless steel Grey cast iron / Aluminium M K ORN 11

12 CUTTING DATA Standard values for cutting speeds v c and medium thickness h m for calculating feed rates by calculating cutting programm»ct«. Material P Carbon steel ardness Brinell Cutting speeds v c (sfm) refering to carbide grade and coating MG12 TN35 TI25 TF45 *35 0.2% C % C medium thickness of chip h m Indexable Insert Type 314 Insert Type 311,313,328,108,111,116 very rigid rigid not rigid very rigid rigid not rigid 0.6% C annealed Alloyed steel quenched quenched high alloyed steel (>5%) annealed hardened M Cast steel Stainless steel unalloyed alloyed martensitic, ferritic austenitic K Grey cast iron low tensile strength high tensile strength Spheroidal graphite cast iron ferritic perlitic Malleable cast iron S eat resistant alloy (Fe) ferritic perlitic annealed hardened eat resistant alloy (Ni, Co) annealed hardened N Al-alloys not heat treatable heat treatable Al-cast-alloy not heat treatable heat treatable Copper-alloys not heat treatable heat treatable ORN *Cermet only indexable insert type 314 available