MFK MFK. High Efficiency Multi-edge Cutter for Cast Iron. Double-Sided Insert with Free Cutting Geometry to Resist Chatter. Cutter for Cast Iron

Transcription

1 Cutter for Cast Iron High Efficiency Multi-edge Cutter for Cast Iron Double-Sided Insert with Free Cutting Geometry to Resist Chatter 1 usable cutting edges per insert ough edge with low cutting forces New CVD grade C42M for longer tool life NEW Ceramic Insert with Chipbreaker Wiper Insert for Finishing

2 Cutter for Cast Iron ough edge with low cutting forces enable stable machining. Uses 1-edge inserts for economical machining. 1 Low Cutting Forces Prevent Chattering Low Cutting Forces with Helical Cutting Edge Design. Cutting Force Comparison (In-house Evaluation) ResultantForce ForceininRadial RadialDirection Direction Resultant ResultantForce Forceininxial xialdirection Direction Resultant 3, 3, 1, 1, 77%% 2, 2, 1,5 1,5 Cutting Cutting Force Force (N) (N) Cutting Cutting Force Force (N) (N) 2,5 2,5 1, 1, R. Max %% Competitor Competitor Competitor CompetitorBB Cutting Conditions: Vc = 18 m/min, fz =.3 mm/t, ap ae = mm, Dry Workpiece: FCD6, ø125 ough and Reliable Insert Construction Prevents Fracturing ough and Reliable Dual ngle Edge Design. Fracture Resistance Comparison (In-house Evaluation) C42M Second Main Cutting Edge First Main Cutting Edge Competitor C (CVD) UP Competitor D (CVD) 25% Cutting ime (min) Cutting Conditions: Vc = 3 m/min, fz =.5 mm/t, ap = mm, Wet Workpiece: FCD45 (4 bores) Burr Comparison Sharp Cutting Prevents Burr Formation Surface Finish Comparison (In-house Evaluation) Chattering Creates Poor Surface Competitor E Cutting Conditions: Vc = 18 m/min, fz =.3 mm/t, ap ae = 3 78 mm, Dry Workpiece: FCD6 1 Competitor F Burr Cutting Direction

3 3 oolholder lineup to meet various applications Fine and Extra Fine Pitch ypes vailable. Fine Pitch Extra Fine Pitch (Example: ø inserts) Recommended for Unstable Setups General Purpose for Wide pplication Ranges 4 5 Recommended for Rigid Setups Finer Pitch for Higher Efficiency Chipbreaker Lineup for Wide Range of pplications General Purpose: GM Chipbreaker (Example: ø inserts) Heavy Duty: GH Chipbreaker Finishing: GL Chipbreaker Wiper Edge: W Chipbreaker (Ground) (Ground) Long ool Life and Stable Machining C42M Features dvanced CVD Coated CRIOS echnology. Longer ool Life Prevents Film Peeling Increased Edge Strength Controlled α-l2o3 crystal growth for improving wear resistance and fracture resistance. 4 % improved film adhesion by optimized interface. Higher film strength and fracture resistance with high aspect ratio icn. icn Layer CRIOS echnology CRIOS echnology CRIOS echnology Conventional Conventional Carbide Substrate CRIOS echnology is Kyocera s original CVD coating technology. Insert Grade Lineup Wear Resistance Comparison (In-house Evaluation).7 C42M Wear (mm).6 Competitor G.5 Fracture Long ool Life (1st Recommendation) C42M Stable Machining Fracture Resistance PR Cutting ime (min) Cutting Conditions: Vc = 2 m/min, fz =.3 mm/t, ap ae = 8 mm, Dry Workpiece: FCD45 Use ceramic insert for high speed machining (see page 3). 2

4 Ceramic Grades for High Speed and High Efficiency Machining Low cutting force ceramic insert with chipbreaker controls edge chipping. Cutting Force Comparison (In-house Evaluation) Resultant Force in Radial Direction 1,5 8 Resultant Force in xial Direction Cutting Force (N) 1, 5 26% Cutting Force (N) % Rake ngle +6.7 Competitor H Competitor I Cutting Conditions: Vc = 6 m/min, fz =.1.25 mm/t, ae ap = mm, DRY Workpiece: FC25, ø125, 1 insert KS65 First Recommendation for Gray Cast Iron 1 High Wear Resistance Enables Stable Machining Reduces grain boundary phase that generates negative impact on the cutting performance. KS65 Conventional Grade Less Grain Boundary Phase Stable Machining Without Chipping More Grain Boundary Phase Unstable Machining Due to Chipping Mechanical and thermal property will be improved by controlling grain boundary phase he grain boundary phase contained a high proportion of glass, therefore its toughness will be weakened by cutting heat Grain Boundary Phase Grain Boundary Phase 2 Sudden Fracture Prevention Crack Propagation Fracture Resistance Improvement L KS65 has higher aspect ratio compared with conventional grade. Bridging Crack Deflection Crack d spect Ratio = L/d Large spect Ratio Controls Crack Propagation CS75 First Recommendation for Nodular Cast Iron Wear resistance improvement due to high coating adhesion. Suitable for high speed cutting. High Wear Resistant Phase (ic Base) Special l2o3 Phase High dhesion Phase (in Base) Si3N4 Substrate 3

5 Face Mill E a ød2 ød b S H 7 E a ød2 ød ød2 ød ød1 ød1 ød1 Fig. 1 Fig. 2 b ød ød1 S 7 H Rake ngle ( ) Description.R. R.R. 8R- -7 1R- -6 (M.) 125R R- ød2 ød b ød3 ød b ød2 ød3 ød5 H H E a G E a G ød4 ød1 øc ød ød1 S 7 Fig. 3 Fig. 4 øc øc1 ød1 ød4 ød6 ød ød1 S 7 oolholder Dimensions Bore Dia. Description Stock Inch Spec Metric Spec Fine Pitch Extra Fine Pitch Fine Pitch Extra Fine Pitch No. of inserts 8R Dimensions (mm) ød ød1 ød2 ød ød1 ød2 H E a b s ød3 ød4 ød5 ød6 øc øc1 G Drawing Weight (kg) Fig R Fig R Fig R Fig R Fig R Fig R MO Fig R Fig R Fig R Fig R Fig R Fig R Fig R MO Fig R-11-8-M Fig R-11-1-M Fig R M Fig R M Fig R-11-2-M Fig R M Fig R M MO Fig R-11-1-M Fig R M Fig R M Fig R M Fig R M Fig R M Fig R M MO Fig : Std. Item MO: Made o Order 4

6 Spare Parts and pplicable Inserts Spare Parts Wedge Wedge Screw Description Wrench 8R-11-8 Spare Parts Mounting Bolt Wedge pplicable Inserts Description 16R C9N W618N 2R R M PNE116NN 25R R-11-2-M PNEG116NR- 25R M R R R C9N W618N 2R R R M 12 2R M PNEG116NR- 25R M R PNEG116NER-W -15 PNE116NN 12 PNEG116NR515 HH1235 PNMG116NEN-GM HH164 PNMG116NEN-GH PNEG116NEN-GL 125R M PNE116NN W618N 1R M PNEG116NER-W -15 C9N 8R-11-1-M PNEG116NEN-GL 125R PNEG116NEN-GL 315R M HH164 PNMG116NEN-GM PNMG116NEN-GH 1R pplicable Inserts PNMG116NEN-GM HH164 PNMG116NEN-GH 125R M PNEG116NER-W -15 Mounting Bolt HH1235 1R-11-1-M PNEG116NEN-GL 125R Wrench 8R-11-8-M HH164 PNMG116NEN-GM PNMG116NEN-GH 1R-11-1 Wedge Screw C9N W618N PNEG116NER-W -15 PNE116NN 12 PNEG116NR R M pplicable Inserts Description Insert Surface Finish Oriented Silicon CVD Silicon Nitride Nitride Ceramic Ceramic C42M PR1525 KS65 CS75 PNMG116NEN-GM PNMG116NEN-GH PNEG116NEN-GL PNEG116NER-W PNE116NN PNEG116NR ough Edge MEGCO NNO General CVD Coated Carbide Dimensions (mm) Wiper Insert (2-edge) High Speed NEW High Speed (with Chipbreaker) : Std. Item 5

7 Recommended Conditions 1st Recommendation 2nd Recommendation Workpiece Material Insert Grade Cutting Speed (m/min) Chipbreaker Feed per ooth fz (mm/t) C42M GM.25 Gray Cast Iron (FC) GH PR1525 GL.12 C42M GM.2 Nodular Cast Iron (FCD) GH PR1525 GL.1 Recommended pplication Range Workpiece : FC Workpiece : FCD ap (mm) W GL GM GH ap (mm) GL W GM GH fz (mm/t) fz (mm/t) Notes : 1. When using W (wiper), please use together with GM or GH. (Not recommended for use with GL) 2. When using wiper, do not exceed fz =.2 or insert corner may be damaged. he main cutting edge of W (wiper) insert is receding from that of GM and GH. herefore, the feed rate for the insert next to W (wiper) is double that of other inserts. Recommended Conditions (Ceramic) 1st Recommendation 2nd Recommendation Without Chipbreaker Workpiece Material Insert Grade Cutting Speed (m/min) Edge Preparation Feed per ooth fz (mm/t) Gray Cast Iron (FC) Nodular Cast Iron (FCD) KS65 CS75 KS65 CS With Chipbreaker Workpiece Material Insert Grade Cutting Speed (m/min) Edge Preparation Feed per ooth fz (mm/t) Gray Cast Iron (FC) Nodular Cast Iron (FCD) KS65 CS75 KS65 CS Recommended pplication Range (Ceramic) Workpiece : FC/FCD 6. Without Chipbreaker ap (mm) 4. With Chipbreaker fz (mm/t) 6

8 Case Studies Machine Base FC25 Base FC , 8 8 Vc = 16 m/min fz =.16 mm/t (Vf = 782 mm/min) ap ae = 3 1 mm Dry 125R (12 Inserts) PNMG116NEN-GM Vc = 16 m/min fz =.18 mm/t (Vf = 917 mm/min) ap ae = 3 14 mm Dry 2R-11-2 (2 Inserts) PNMG116NEN-GM C42M Chip Removal Rate Competitor J (12 Inserts) 125cc/min 235cc/min Efficiency 2 imes Chip Removal Rate C42M Competitor K (12 Inserts) 167cc/min 385cc/min Efficiency 2.3 imes Little noise and vibration with increased cutting speed and feed rate. (User Evaluation) C42M performed at 2.3 times the efficiency of Competitor K. Little noise and stable machining. (User Evaluation) Mold Part FCD6 Bed FC3 2.2m 1m Vc = 9 m/min fz =.34 mm/t (Vf = 974 mm/min) ap ae = 2 6 mm Dry 8R-11-8 (8 Inserts) PNMG116NEN-GM PR1525 Vc = 15 m/min fz =.26 mm/t (Vf = 1,242 mm/min) ap ae = 3 1 mm Dry 16R (16 Inserts) PNMG116NEN-GM C42M Machining Efficiency PR1525 Competitor L (8 Inserts) 1pcs/edge 3pcs/edge ool Life 3 imes Chip Removal Rate C42M Competitor M (8 Inserts) 372cc/min 93cc/min Efficiency 4 imes Competitor L had chipping after machining 1pc. PR1525 kept good edge condition and stable machining after machining 3 pcs. (User Evaluation) C42M improved the efficiency by 4 times compared with Conventional M. (User Evaluation) 215 KYOCER Corporation CP354