System DC. GROOVE MILLING and THREAD MILLING. Thread milling partial profile Thread milling full profile Groove milling Chamfer milling

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1 GROOVE MIING and THREAD MIING System DC Thread miing partia profie Thread miing fu profie Groove miing Chamfer miing 1

2 DC THREAD MIING CUTTER Partia profie Metric ISO-thread DIN13-20 Partia profie DCG Thread M1 - M2.5 Part number Thread D min Z P d 1 d 3 DCG.3.M M DCG.3.M M DCG.3.M M DCG.3.M M DCG.3.M M DCG.3.M M DCG.3.M M DCG.3.M M DCG.3.M M on stock Δ weeks P ο main recommendation M ο aternative recommendation K uncoated grades N coated grades S brazed/cermet H 2

3 DC THREAD MIING CUTTER Partia profie Metric ISO-thread DIN13-20 Partia profie DCG Thread M3 - M12 Part number Thread D min Z P P max d 1 d 3 DCG.3.M DCG.3.M M DCG.3.M DCG.3.M M DCG.3.M M DCG.3.M DCG.3.M M DCG..M DCG..M M DCG..M DCG..M DCG..M M8-M DCG..M DCG..M DCG..M DCG..M M10-M on stock Δ weeks P ο main recommendation M ο aternative recommendation K uncoated grades N coated grades S brazed/cermet H ο 3

4 DC THREAD MIING CUTTER Fu profie Metric ISO-thread DIN13-20 Fu profie DCG Thread M3 - M12 Part number Thread D min Z P d 1 d 3 DCG.3.M DCG.3.M M DCG.3.M M DCG.3.M DCG.3.M M DCG.3.M DCG.3.M M DCG..M DCG..M M DCG..M DCG..M M DCG..M DCG..M DCG..M M DCG..M DCG..M DCG..M DCG..M M DCG..M DCG..M on stock Δ weeks P ο main recommendation M ο aternative recommendation K uncoated grades N coated grades S brazed/cermet H ο

5 DC THREAD MIING CUTTER Unified American Unified thread UNF / UNC / UNEF DCG Thread #5-0 7/16' ' - 20 Part number Thread D min Z P d # # DCG #5 0 UNC DCG #5 UNF DCG #6 32UNC 8 32UNC DCG #6 0 UNF DCG #8 36 UNF DCG #10 2UNC 12 2UNC DCG /' ' 20 UNC DCG /' ' 28 UNF DCG /16' ' - 18 UNC DCG /8' ' - 16 UNC DCG /16' ' - 1 UNC DCG /16' ' - 20 UNF DCG /2' ' - 13 UNC on stock Δ weeks P ο main recommendation M ο aternative recommendation K uncoated grades N coated grades S brazed/cermet H ο 5

6 DC THREAD MIING CUTTER Whitworth Whitworth thread "medium cass" BSW / BSF DCG Thread 1/8''-1/2'' Part number Thread D min Z P d 1 DCG /8'' - 0 BSW DCG /32'' - 32 BSW DCG /16'' - 2 BSW DCG /16'' - 32 BSF DCG /32'' - 2 BSW DCG /32'' - 28 BSF DCG /'' - 20 BSW DCG /'' - 26 BSF DCG /32'' - 26 BSF DCG /16'' - 18 BSW DCG /16'' - 22 BSF DCG /8'' - 16 BSW DCG /8'' - 20 BSF DCG DCG /16'' - 1 BSW DCG DCG /16'' - 18 BSF DCG DCG /2'' - 12 BSW DCG DCG /2'' - 16 BSF on stock Δ weeks P ο main recommendation M ο aternative recommendation K uncoated grades N coated grades S brazed/cermet H ο 6

7 DC THREAD MIING CUTTER Whitworth Whitworth pipe thread DCG Thread G 1/16''-3/8'' Part number Thread D min Z P d 1 DCG..55.G G 1/16'' DCG..55.G G 1/8'' DCG..55.G G 1/'' DCG..55.G G 3/8'' on stock Δ weeks P ο main recommendation M ο aternative recommendation K uncoated grades N coated grades S brazed/cermet H ο 7

8 DC GROOVE MIING CUTTER Fu radius Groove miing DCR Cutting edge Ø Fu radius Depth of groove ( mm) ( mm) ( mm) Part number Z w t max r d 1 d 3 DCR DCR DCR DCR DCR DCR DCR DCR DCR DCR DCR DCR DCR on stock Δ weeks P ο main recommendation M ο aternative recommendation K uncoated grades N coated grades S brazed/cermet H ο 8

9 DC GROOVE MIING CUTTER Groove miing DCN Cutting edge Ø Width of groove Depth of groove ( mm) ( mm) ( mm) Part number Z w t max r d 1 d 3 DCN DCN DCN DCN DCN DCN DCN DCN DCN DCN DCN DCN DCN DCN on stock Δ weeks P ο main recommendation M ο aternative recommendation K uncoated grades N coated grades S brazed/cermet H ο 9

10 DC GROOVE MIING CUTTER Groove miing DCX Cutting edge Ø Width of groove Depth of groove ( mm) ( mm) ( mm) Part number Z w t max d 1 d 3 AS5 DCX DCX DCX DCX DCX DCX DCX DCX DCX DCX DCX DCX DCX DCX DCX DCX DCX DCX on stock Δ weeks P main recommendation M ο aternative recommendation K uncoated grades N ο coated grades S brazed/cermet H 10

11 DC CHAMFER MIING CUTTER Chamfer miing DCF Cutting edge Ø Width of chamfer Size of chamfer ( mm) ( mm) Part number Z w Chamfer t max d 1 d 3 DCF DCF DCF DCF DCF DCF DCF DCF DCF on stock Δ weeks P ο main recommendation M ο aternative recommendation K uncoated grades N coated grades S brazed/cermet H ο 11

12 CUTTING DATA Standard vaues for cutting speeds v c and Feed/tooth fz Materia Hardness Brine (HB) Cutting speed v c Feed/tooth fz P 0.2% C Carbon stee 0,% C ,6% C anneaed 180 Aoyed stee quenche80 quenched high aoyed stee (>5%) anneae00 hardened Cast stee unaoyed 180 aoye M Stainess stee martensitic, ferritic 200 austenitic K Grey cast iron ow tensie strength 180 high tensie strength Spheroida graphite cast iron ferritic 160 peritic N Maeabe cast iron A-aoys ferritic 125 peritic 225 not heat treatabe heat treatabe up to max. A-cast-aoy not heat treatabe 80 heat treatabe Copper-aoys not heat treatabe 90 heat treatabe S Heat resistant aoy (Fe) Heat resistant aoy (Ni. Co) anneae00 hardene75 anneae50 hardened

13 TECHNICA INSTRUCTIONS Feed rates and time cacuation It is simpe and easy to cacuate your speed and feeds using HORN'S HCT program. We recommend that you cacuate the cutting data with this program as it wi provide you with the best cutting performance and resuts. Basic features of the cacuations can be found on the fowing pages. HCT (HORN Circuar Technoogy) - safe and fast - Your cutting data for groove miing by circuar interpoation of interna and externa grooves as we as groove miing of inear grooves. System requirements from Windows 95. Avaiabe on CD-ROM. BASIC RECOMMENDATIONS Overhang of the miing cutter Seect the shortest possibe camping device and miing shank, to contro the runout toerance of the toos. arge cutting widths in combination with ong overhangs require specific manufacturing methods such as dividing the cutting width to achieve the best possibe cutting resut due to reduced cutting forces. Diameter of the miing cutter When using a arge diameter cutter, whose reationship is cose to the bore diameter, manufacturing cycetime can be reduced, due to the smaer center of rotation and higher feed rates. Many times the rotation of the miing cutter center wi be defined by the parameters of the workpiece and the whoe appication setup. Thread miing With HORN thread miing inserts the thread profie is generated in one fu cut to the profie depth of the thread. This produces threads with minima taper especiay in high aoyed stees. In bind hoes it is recommended to mi from the bottom to the top. Otherwise there is the risk of damaging the too because of miing into chips at the bottom of the bind hoe. A genera recommendation for thread miing: The miing cutter diameter shoud not exceed 70% of the minor diameter of the thread. Otherwise recutting of the profie occurs which coud bring the whoe thread out of toerance. 13

14 TECHNICA INSTRUCTIONS Miing direction Most HORN miing toos are right handed, and it is recommended to use them with the cimb miing process as this is generay recommend for carbide toos. Miing entry into the workpiece Ramp ange > 5 A simpe radia entry of the miing cutter creates a very ong contact ange which eads to vibrations which wi not disappear for the rest of the miing operation and are visua on the bottom of the groove. It is recommended to enter the groove with a ramp ange of 5 up to 180 to the maximum depth of cut. The cacuated cutting data refers to the miing condition when the insert is in the fu cut but can be aso used for the entry oop. 1

15 GROOVE MIING by circuar interpoation MIING OF AN INTERNA GROOVE Cos [180 - φ ] = r2 + [R + a r - r] 2 - R φ φ 2r [R + a r - r] = ϖ 2r φ mm 360 ength of cut t = A T n z A z min Time for cut (for A T ) A Z = h m mm 2 Area of chip s' 1 = ϖ 2 (R-r+a r ) mm/min t Feed rate of too centre A T = ϖ [(R + a r ) 2 - R 2 ] mm 2 Area of groove section s' 2 = s' 1 R + a r mm/min R - r + a r Feed rate of too tip Specification Feed rate Specification s' ISO Specification v f Specification ISO Specification Radius of cutter r r Revoutions n n Radius of workpiece R R Number of teeth z z Feed rate of too centre s 1 v f 3 Feed/tooth s z f z medium thickness of chip h m h m Feed rate of too tip s 2 v f2 radia depth of cut a r a e HCT (HORN Circuar Technoogy) - safe and fast - Your cutting data for groove miing by circuar interpoation of interna and externa grooves as we as groove miing of inear grooves. System requirements from Windows 95. Avaiabe on CD-ROM. 15

16 FORMUAS Z = Number of teeth d = Cutting edge Ø [mm] n = Revoutions n = v 1000 c d ϖ [1/min] [RPM] v c = Cutting speed v c = d ϖ n [m/min] /.308 = sfm 1000 f z = Feed/tooth f z = v f Z n [mm] / 25. = inch f = Feed per revoutions f = f z Z [mm/u] [mm/rev] v f = Feed rate v f = f z Z n [mm/min] / 25. = inch/min Notes 16