MILLING CUTTERS MILLING CUTTERS

Transcription

1 MILLIG CUTTERS

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3 Tool Type Quality Stadard Page o ED MILLS - SHORT SERIES - TYPE B ED MILLS - LOG SERIES - TYPE B ED MILLS - SHORT SERIES - TYPE B - TIC COATED ED MILLS - LOG SERIES - TYPE B - TIC COATED ED MILLS - SHORT SERIES - TYPE BW ED MILLS - LOG SERIES - TYPE BW ED MILLS - SHORT SERIES - TYPE BF ED MILLS - SHORT SERIES - TYPE BR ED MILLS - LOG SERIES - TYPE BR ED MILLS - LOG SERIES - TYPE BF SLOT CUTTERS BALL OSED ED MILLS - SHORT SERIES BALL OSED ED MILLS - LOG SERIES WOODRUFF KEYSEAT CUTTERS - STAGGERED TEETH T- SLOT CUTTERS - STARGGERED TEETH DOVETAIL CUTTERS SIGLE FLUTE ALUMIIUM ED MILLS SIGLE FLUTE ALUMIIUM ED MILLS MORSE TAPER ED MILLS - SHORT SERIES - TYPE B MORSE TAPER ED MILLS - LOG SERIES - TYPE B MORSE TAPER ED MILLS - SHORT SERIES - TYPE BR MORSE TAPER ED MILLS - SHORT SERIES - TYPE BF DRILLIG - MILLIG COMBIED TOOLS SHELL ED MILLS SIDE AD FACE CUTTERS - STRAIGHT TEETH SIDE AD FACE CUTTERS - STAGGERED TEETH AGULAR CUTTERS DOUBLE AGLE COCAVE RADIUS CUTTERS COVEX RADIUS CUTTERS - E (%Co) - E (%Co) - E (%Co) - E (%Co) - E (%Co) - E (%Co) - E (%Co) - E (%Co) - E (%Co) - E (%Co) - E (%Co) - E (%Co) - E (%Co) - E - E - E - E (%Co) - E (%Co) - E - E - E - E /B /B 0/D 1/B 1/C MTE orm MTE orm MTE orm 10 /B /A E. Catalogue

4 Applicatio Examples of Millig Cutter Types Plai Millig Cutter Shell Ed Mill Side ad Face Millig Cutter Adjustale Side ad Face Millig Cutter Side ad Face Millig Cutter Covex Millig Cutter Cocave Millig Cutter Adjustale Millig Cutter Corer Radius Millig Cutter

5 Applicatio Examples of Millig Cutter Types T-Slot Cutter Woodruff Millig Cutter Agular Millig Cutter Sigle - Agled Millig Cutter Doule - Agled Millig Cutter Doule - Agled Millig Cutter Corer Radius Millig Cutter Dovetail Cutter Dovetail Cutter

6 Millig Cutters Types ad Materials The appliciatio of millig cutters accordig to the tool type is show o Tale 1 elow; the chip reaker form raughig millig cutters Tale ; usig area accordig to the material is show Tale. Tale1 Tool Type TS Areas of Usage Tale Tool Type Areas of Usage H W S Y Materials with ormal resistace ad hardess values Hard, hard ductile materials with high resistace ad short chippig materials Soft, ductile ad / or log chippig materials F HF R HR Roughig & Fiishig Roughig Tale A- Steel ad steel cast materials Descriptio of Material Tesile Resistace (/) from up to Millig Cutter Types H W F R HF HR Automate Steel Costructio Steel Stailess steels ad stailess steel cast itruratio Steel Steel Cast Tougheed Steel Tool Steel Cast Iro Tempered Cast o-alloyed Alloyed Softeed Tougheed Soft or tempered o alloyed, tougheed Alloyed, tougheed Alloyed, tougheed o-alloyed or alloyed, softeed High caro ad / or high alloyed softeed, fied Graphite Roud Graphite Hardess 10 Hardess (HB) (HB) Tale B - o Ferrous Metals Descriptio of Material Tesile Millig Cutter Types Stregth (/) from to H W F R HF HR Alumiium cast alloy with up to % Si - 10 Alumiium cast alloy with more tha % Si Copper Low resistace, High copper cotet Copper ad High resistace, low or Copper alloys High copper cotet Chip reakig characteristic (alloyed i P1 Ph1Te alloyed) Magesium ad Mg. alloys Titaium alloys Medium resistace Low resistace

7 Tool Types ad Operatig Values of Millig Cutters Accordig to the Material V= Cuttig speed (m/mi.) f= feed per (/thread) F = Feed (/mi)=f... = umer of threads of millig cutter = umer of revolutio of millig cutter (revolutio/miute) Type of Material Millig cutter material Shell Ed Mills Side ad Face Millig Cutters V f Tip V f Tip o-alloyed steels Up to 00 / o-alloyed ad alloyed steels Up to 00 / o-alloyed ad alloyed steels Up to 00 / o-alloyed ad alloyed steels Up to / Alumiium alloys (soft) Alumiium alloys (medium, hard) Alumiium alloys (hard) Grey cast iro Up to 0 HB Grey cast iro higher tha 0 HB Tempered Cast Up to 0 HB Steel Cast Up to / Brass (soft) Brass-Broe (hard) H H W -W -W H (H) W H H W -W -W H (H) W The tale values aove are give as referece values; - For materials with homogeeous structure, - For stale machie ad stale fixig coditios; - For proper coolig coditios; - For perpedicular positioig of the tool to the axis of the work piece.

8 Recoeded Operatig Coditios for Ed Mills Material Structural, itride Steels, Automate Steels, Tempered Steels > / Tool Steels Gray Cast Iro GG<0HB Cuttig speed (m/mi.) B / 7 / D umer of Diameter () I II III IV V VI VII Acid ad Heat resistat Steel, Alloyed Steel < 00/ Tempered ad Tool Steels, Gray Cast Iro GG>0HB Alloyed Steel < 0 / Valve Steel, Cold Work Steels, Speed Steels, Acid Resistat Steels Difficult Chip Removal Steels, High Temperature Resistat Steels, Ti ad i Alloyed Steels Alumiium with o-hardeed Surface, Al - Mg Alloy Alumiium Cast <= % Si Alumiium with o-hardeed Surface Alumiium Cast >= % Si Copper Brass, Copper Alloys Ti Coated Ti Coated Ti Coated Ti Coated Ti Coated Ti Coated Ti Coated f f f f f f f f f f f f f f d 0.xd 7/D 1.xd 0.xd B/ f: Feed per thread (/thread) : Rev. (rev/mi) vf: Total feed per miute (m/mi)

9 f: Feed per thread (/thread) : Rev. (rev/mi) vf: Total feed per miute (m/mi) Material Structural, itride Steels, Free Cuttig Steels, Tempered Steels > / Tool Steels Gray Cast Iro GG<0HB B / R r. B / R r.1 I II III IV V VI VII Acid ad Heat resistat Steel, Alloyed Steel < 00/ Tempered ad Tool Steels, Gray Cast Iro GG>0HB Alloyed Steel < 0 / Valve Steel, Cold Work Steels, Speed Steels, Acid Resistat Steels Difficult Chip Removal Steels, High Temperature Resistat Steels, Ti ad i Alloyed Steels Alumiium with o-hardeed Surface, Al - Mg Alloy Alumiium Cast <= % Si Alumiium with Hardeed Surface Alumiium Cast >= % Si Copper Brass, Copper Alloys Ti Coated Ti Coated Ti Coated Ti Coated Ti Coated Ti Coated Ti Coated f f f f f f f f f f f f f f xd d B/R r.1 1.xd 0.xd B/R r. Recoeded Operatig Coditios for Ed Mills Cuttig speed (m/mi.) umer of Diameter ()

10 Ø Ø ED MILLS - SHORT SERIES - TYPE B (% Co) B js1 B007 B007 B0070 B007 B0070 B007 B0070 B007 B0070 B007 B00710 B B0070 B007 B007 B00710 B007 B00710 B007 B0071 B007 B00710 B0071 B00710,0,,0,,0,,0,,0, 7,0 7,,0, 9,0 9,,0, 11,0 11,,0, 1,0 1, B0071 B0071 B00711 B0071 B007 B007 B0071 B007 B007 B00710 B007 B00710 B0071 B007 B00710 B0070 B007 B007 B007 B007 B007 B007 B0070 1,0 1,0 17,0 1,0,0,0 1,0,0,0,0,0,0 7,0,0 9,0 0,0,0,0,0,0,0,0 0, * Over ø Producig from (%Co)

11 ED MILLS - LOG SERIES - TYPE B B00 B00 B000 B000 B000 B000 B0070 B000 B00 B00 B00710 B00 B007 B0070 B007 B007, B0071 B007 B00710 B00 B00 B0070 B00 B0070 B00 B000 B00 B00 B00 B00 B (% Co) B js1 * Over ø Producig from (%Co) 7

12 (% Co) B js1 TIC ED MILLS - SHORT SERIES - TYPE B - TIC COATED Ø Ø B17 B170 B170 B170 B170 B170,0,0,0,0,0, B17 B17 B1710 B171 B171 B17,0,0 1,0 1,0 1,0, (% Co) B js1 TIC ED MILLS - LOG SERIES - TYPE B - TIC COATED B10 B10 B10 B10,0,0,0,0 B1 B1 B17 B1,0,0 1,0, * Over ø Producig from (%Co)

13 (% Co) BW js1 ED MILLS - SHORT SERIES - TYPE BW Ø Ø B00710 B007 B007 B007 B007 B007 B00710 B00710 B0071 B007,0,0,0,0,0,0,0,0 1,0 1, B007 B00710 B00710 B0071 B00710 B0071 B00710 B007 B ,0,0,0,0,0,0,0 0,0, (% Co) BW js1 ED MILLS - LOG SERIES - TYPE BW B000 B000 B000 B000 B000 B00 B00 B0070 B B007 B00 B00 B0070 B00 B0070 B00 B000 B * Over ø Producig from (%Co) 9

14 (% Co) BF js1 ED MILLS - SHORT SERIES - TYPE BF B00 B0070 B0070 B007 B0079 B0079 B00,0,0,0 1,0 1,0 1,0, B0070 B00 B00 B00 B00 B000 B00,0,0,0,0,0 0,0, (% Co) BR js1 ED MILLS - SHORT SERIES - TYPE BR B0070 B007 B007 B00770 B0077 B0077 B0070,0,0,0 1,0 1,0 1,0, B0070 B00 B00 B00 B00 B000 B00,0,0,0,0,0 0,0, * Over ø Producig from (%Co)

15 (% Co) BR js1 ED MILLS - LOG SERIES - TYPE BR B007 B00770 B00770 B0077 B00779 B00779 B B0070 B007 B0070 B007 B0070 B00 B (% Co) BF js1 ED MILLS - LOG SERIES - TYPE BF B00790 B00790 B0079 B00799 B00799 B00790 B B007 B0070 B007 B0070 B00 B * Over ø Producig from (%Co) 1

16 SLOT CUTTERS B0070 B0070 B00 B00 B00 B00 B007 B00 B0070 B007, B007 B007 B0071 B00710 B0071 B0071 B00711 B0071 B007 B (% Co) 7/D e Ø Ø * Over ø Producig from (%Co)

17 (% Co) /B js1 BALL OSED ED MILLS - SHORT SERIES R R B0000 B0000 B000 B B00 B0070 B0070 B (% Co) /B js1 BALL OSED ED MILLS - LOG SERIES R R B0000 B0000 B000 B000 B B0070 B0070 B000 B000 B , 1 * Over ø Producig from (%Co)

18 0/D WOODRUFF KEYSEAT CUTTERS - STAGGERED TEETH Ø Ø L (e) L (e) L B00000 B000 B00000 B0000 B0000 B0010 B0000 B00 B000 1, 1, 1, 1, 1,,,,, B00 B00 B001 B00 B0010 B0000 B0000 B000 B000,,,,,,,,, /B T- SLOT CUTTERS - STARGGERED TEETH Ød Ø Ø (e) d (e) d B001 B00 B0011 B0011 B0010 B00 11,0, 1,0 1,0 1,0,0.0,0,0,0 9,0 11,0 1 7, 7,0,0 70,0 7,0,0 B00 B001 B001 B00 B001,0,0,0 0,0,0,0 1,0 1,0 1,0, ,0,0,0,0 11,0 * Over ø Producig from (%Co)

19 (% Co) 1/C js1 DOVETAIL CUTTERS Ø Ø L L L B00 B0000 B0000 B x x x x,0,0,, B00 B0000 B0000 B x 0 x 0 x 0 x 0,,0,0,

20 (% Co) MTE h9 SIGLE FLUTE ALUMIIUM ED MILLS Ø Ø (h) (h) B0000 B0000 B00 B0000 B B0000 B00 B0000 B00 B (% Co) MTE h9 SIGLE FLUTE ALUMIIUM ED MILLS Ø Ø (h) (h) B00 B00 x x 0 0 B00 x 0 * Over ø Producig from (%Co)

21 B js1 MORSE TAPER ED MILLS - SHORT SERIES - TYPE B Ø B001 B001 B00000 B000 B0000 B0000 B B000 B00 B00 B0000 B00 B B js1 MORSE TAPER ED MILLS - LOG SERIES - TYPE B Ø B00 B00 B00000 B000 B000 B B0000 B00000 B000 B0000 B * Over ø Producig from (%Co) 7

22 BR js1 MORSE TAPER ED MILLS - SHORT SERIES - TYPE BR Ø B007 B007 B000 B0070 B00 B B00 B000 B00 B00 B BF js1 MORSE TAPER ED MILLS - SHORT SERIES - TYPE BF Ø Mors Taper r Mors Taper r B007 B007 B00 B00 B00 B B00 B000 B00 B00 B * Over ø Producig from (%Co)

23 MTE h 11 DRILLIG - MILLIG COMBIED TOOLS 11 Ø Ø B0000 B js1 SHELL ED MILLS Ø Ø (H7) (k1) (H7) (k1) B B B B B * Availale upo request 9

24 SIDE AD FACE CUTTERS - STRAIGHT TEETH /B js1 (H7) B00000 B0000 B0000 B0010 B0000 B0000 B0000 B0000 B00 B0000 (k11) (H7) B000 B00000 B000 B0000 B0000 B0000 B0000 B0000 B00 (k11) Ø Ø SIDE AD FACE CUTTERS - STAGGERED TEETH (H7) B B B00000 B00000 B00010 B00000 B00000 B00000 B00000 B000 (k11) (H7) B00000 B0000 B B0000 B0000 B00000 B00000 B00000 B00000 B000 (k11) /A js1 Ø Ø * Availale upo request 70

25 Ø Ø Ø Ø AGULAR CUTTERS H js1 B00000 B00000 B0000 B00000 B0000 B B B B B00000 B B B00000 B B (H7) (js1) * Availale upo request DOUBLE AGLE B00000 B0000 B00000 B0000 B00 B B00 B0010 B00000 B0000 B00000 B (H7) (js1) (H7) (js1) 7 H js1 71 (H7) (js1)

26 Ø Ø r Ø r Ø COCAVE RADIUS CUTTERS (H7) B00 B0010 B B00 B00 B000 (js1) r (H11) ,0,0,0 9,0,0,0 1,00 1, 1,0,00,0,00 js1 (H7) B00101 B000 B000 B000 B00 B000 (js1) r (H11) ,0 1,0,0,0,0,0,1,00,00,00,0,00 COVEX RADIUS CUTTERS (H7) B000 B00 B0010 B000 B000 B0000 (js1) r (H11) ,0,,,0,0,0 1,00 1, 1,0,00,0,00 js1 (H7) B001 B0000 B0000 B0000 B000 B0000 (js1) r (H11) ,,0,0,0, 1,0,1,00,00,00,0,00 * Availale upo request 7

27 Ali Usta says; Millig cutters are tools which are suject to the highest level of mechaic forces i machiig. Millig cutters are cuttig tools for threadig surfaces, holes ad chaels also used for special forms ad threads for machiig o metal, plastic, etc materials. Millig cutters are divided ito two classes: Drillig millig cutters; used y coectig from holes to the chuck. Cylidrical ad Morse tamper shak millig cutters; used y coectig to tool holders MK shells. Ali Usta recoeds: Use differet types of millig cutters for each material to e processed. Ali Usta; I choosig millig cutters we must pay attetio to the followig: Millig cutters are chose depedig o the coectio positios of millig cutters, type of the material ad the side or face cuttig positio of the millig cutter. I choosig the correct type of millig cutters we must pay attetio to the type of steel made from. Millig cutters maufactured Type : umer of cuttig edges, chip ad helical legth ormal Type H: umer of cuttig edges, more chip ad helical agle less tha ormal Type W: umer of cuttig edges, more chip ad helical agle more tha ormal Materials of Millig Cutters Coalt alloyed high speed steel () Solid caide metals I additio: TITAIUM ITRIDE (TI) AD TITAIUM CARBO-ITRIDE (TIC) surface coatigs ca e used. Use TYPE for ductile, log chippig materials with medium hardess ad ormal resistace (o-alloyed or low-alloyed steels, grey cast iro, tempered cast ad rass materials) Use TYPE H (or S) for hard ad rittle materials which medium ad short chippig (alloyed steel, cast steel, hard gray cast iro ad rass materials) Use TYPE W (or Y) for soft, log chippig materials with low resistace (Alumiium ad soft alumiium alloys, soft rass, MS, copper ad copper alloys) Ali Usta remids to keep the followig priciples always i mid: Whe proceed from soft materials to hard materials, i other words, from low resistat to high resistat materials, cuttig speed ad progress gradually decreases. The chips are the iggest eemy of the cuttig tools; therefore chips must e iediately removed away from the work piece ad tool. If ecessary, etter use rough machiig cutters. TI coated tools must e operated with higher revolutios tha ucoated tools. The work piece ad the ed mills must e coected to the machie as close as possile. Do ot use millig cutters with lut ad wor cuttig edges. Must e preferred a dow millig (i cocurret directio) as far as possile. Chuck must e esured the clea, without urr ad oil-free spidle, the tool's axis ad the shaft's axis must match each other. 7

28 Ali Usta presets the prolems ecoutered i millig, their causes ad solutios. 1- Breakig of the cuttig edges CAUSE 1.1. Too much feed 1.. Work piece is ot rigid 1.. Cuttig tool is ot fixed tightly 1.. The staility of cuttig tool is iadequate 1.. Threads are too sharp SOLUTIO Feed must e decreased More rigid machie or coectio devices is required Coectig ut must e assemled Must e used short type tool or short coectio holder. Chage the rake agle or chamfer the sharp edges - Too much wearig CAUSE.1. Cuttig speed is too high.. Work piece is too hard.. Formatio of tempered chips.. Usuitale feed speed (too high).. Usuitale cuttig agle.. Back of the cuttig edge scuffs SOLUTIO Reduce speed ad use coolat Use Ti coated ed mill Reduce the cuttig speed Reduce feed rate Choose cuttig agle as per material Icrease the clearace agle - Viratio CAUSE.1. Feed rate ad cuttig speed are too high.. Cuttig tool ad coectig system are ot suitale.. Clearace agle is too large.. Work piece is improperly coected.. Cuttig depth too large.. Cuttig tool is too log or total legth is too log - Difficulty i chip removal CAUSE.1. Chip volume is too much.. The chip flute is arrow i millig at the ottom of thread.. Isufficiet coolig - Bad surface quality CAUSE.1. The chose feed rate may e too large.. Cuttig speed is too low.. Wear out i cuttig tool may e high.. Formatio of lue chips SOLUTIO Suitale cuttig values must e used More rigid tool ad coectio must e used Adjust the margi Work piece must e coected properly Cuttig depth must e reduced Cuttig tool must e coected shorter or short millig cutter must e chose SOLUTIO Reduce the feed ad cuttig speed's rates Use a ed mill with less threads ad wide fluted Icrease coolig pressure SOLUTIO Reduce the feed rate Icrease the speed Make poit sharpeig i short period Reduce the cuttig speed 7