AHX Series TOOLS NEWS. Heptagonal double sided insert. Economical 14 cutting edge inserts.

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1 TOOL NEW Update B195E General Purpose Multi Corner Insert Type Face Milling Cutter AHX eries Heptagonal double sided insert. Economical 14 cutting edge inserts. eries Expansion

2 General Purpose Multi Corner Insert Type Face Milling Cutter AHX eries Unique 14 cornered insert Economical heptagonal double sided insert Double positive cutting edge geometry offers lower cutting resistance for improved machining efficiency. (mm) Tool Holder Number AHX AHX High rigidity by increasing the thickness of the inserts Corner number is clearly shown 1

3 A Unique Face Mill for Machining of teel, tainless teel and Cast Iron AHX440 AHX640 Designed to control abnormal insert breakage and body damage The unique conical insert seat and Anti Fly mechanism (A.F.I) hold the insert securely. The outer edge of the insert is not in contact with the body, thereby preventing damage if sudden fracturing occurs. The thick insert negates the need for a shim. Contact surface Through coolant holes Improves chip discharge and prevents chip welding. Number of tooth (mm) AHX440 AHX

4 BAKER YTEM Breaker series for varied cutting condition Focus on cutting edge sharpness table Cutting (Continuous cutting, Without scale, etc.) Unstable Cutting (Interrupted cutting, With scale, etc.) Focus on cutting edge strength Lbreaker Mbreaker R andhbreaker The high rake angle boosts cutting performance. Positive land retains strength and provides low cutting resistance. First recommendation for general applications. A good balance of edge strength and sharpness is provided by the optimized positive land and rake angle. For unstable applications. Enhanced edge strength and retention of sharpness is provided by the negative land and positive rake angle respectively. Work Material Cutting Condition Light General Heavy P AHX440 L With Wiper M (R0.8) With Wiper M (R3.2) Not with Wiper R Not with Wiper AHX640 MP M AHX440 L With Wiper M (R0.8) With Wiper M (R3.2) Not with Wiper R Not with Wiper AHX640 MM K AHX440 L With Wiper M (R0.8) With Wiper M (R3.2) Not with Wiper R Not with Wiper AHX640 MK HK Wiper Insert of AHX640 Based on the number of inserts and the cutting conditions, use of wiper inserts can improve overall surface fi nishes. P K WP + combination with MP Double side 2 corners. WK + combination with MK Right-hand 2 corners, left-hand 2 corners. 3

5 Face Milling Cutter for High Efficiency Machining of Cast Irons AHX640W High rigidity inserts suitable for high feed milling of cast irons loped cutting edge and large rake angle Innovative clamp system New wedge geometry developed to increase the permissible number of teeth. Unique wedge geometry uses a protruding section that fits inside the insert hole acts as an Anti-Fly Insert (AFI) mechanism. 2 variations for different applications Extra fi ne pitch and super extra fi ne pitch types allow high effi ciency milling under various machining conditions. Additionally, left hand type for use on special machines are also available as standard. Inserts can be used with both right and left hand type cutters. Prevents insert from flying out of the pocket. Feed per tooth (mm/t.) uper extra fi ne pitch Extra fi ne pitch Higher rigidity Conditions Lower rigidity Insert applications MK HK table Cutting Unstable Cutting MK General-purpose insert HK trong cutting edge insert WK Wiper insert High tolerance M-class insert. Neutral, double sided 14 corners. 20º rake angle for low cutting resistance. First recommendation for roughing and fi nishing. 20º rake 0º rake High tolerance M-class insert. Neutral, double sided 14 corners. High cutting edge strength to prevent fracturing of the cutting edge during unstable machining of non-uniform work pieces and high feed machining. + Improved surface finish Right-hand 2 corners, left-hand 2 corners. Based on the number of inserts and the cutting conditions, by using the wiper inserts it is possible to improve the overall surface fi nish. 4

6 Insert grades for a wide range of materials MIRACLE IGMA accumulated Al-Ti-Cr-N based PVD coating Dramatically improving the heat and wear resistance Excellent welding resistance due to low coefficient of friction PVD accumulated coating (Each damage measures) pecial cemented carbide substrate Heat resistance Oxidation temperature (Cº) Conventional MP6100 MP Hardness (Hv) Wear resistance Excellent welding resistance due to low coefficient friction Coefficient of friction Work Material Grade Measured at 600 degress 55C U304 P Carbon teel, Alloy teel MP M tainless teel MP Conventional TOUGH-Σ Technology A fusion of the separate coating technologies; PVD and multi-layering realises extra toughness. PVD accumulated coating Base layer High Al-(Al, Ti)N The new technology Al-(Al, Ti)N coating provides stabilisation of the high hardness phase and succeeds in dramatically improving wear, crater and welding resistance. Each grade has a layer suitable for each application area P M (Al,Cr)N Tough against thermal Cracks TiN Tough against notching Graphical representation. election standard IO Application range PVD IO Application range PVD IO Application range CVD PVD IO Application range PVD P teel P10 P20 P30 P40 MP6120 MP6130 M M10 tainless teel M20 M30 M40 MP7130 MP7130 MP7140 K Cast Iron K01 K10 K20 K30 FH7020 VP20RT H Hardened teel H10 H20 H30 H40 5

7 Features of has excellent wear, chipping and thermal crack resistance. These features prevent the problems usually associated with machining cast irons over prolonged periods. Improved wear resistance The micro-grain wear resistant Al2 O 3 and fi brous TiCN layers deliver excellent wear resistance when milling a wide range of cast irons. Improved fracture resistance Use of a specially developed cemented carbide that provides superior resistance to fracture and thermal cracking prevents the cutting edge from sudden fracturing. Reduced abnormal damage A black super-smooth coating prevents abnormal damage such as weld chipping. tructure of Black super-smooth coating Comparison of Coating urface Cutting Performance Conventional coating Black super-smooth coating Wear Resistance Flank wear width VB(mm) Wear comparison when machining with a single tooth Large wear Conventional B Large wear Conventional A Cutting length (m) urface Finish (!m) Ra=0.26!m Rz=2.58!m Rz.jis=1.68!m (mm) <Cutting Conditions> Workpiece : FC300 Tool : AHX640WR10010D Insert : NNMU200608ZEN-MK (1 piece) Cutting speed : 300 m/min Feed per Tooth : 0.3 mm/tooth Axial Depth of Cut : 5 mm Cutting mode : Dry <Finish condition> <Cutting Conditions> Workpiece : FCD700 Tool : AHX640WR10014D Insert : NNMU200608ZEN-MK(13 piece) Wiper insert : WNEU2006ZEN7C-WK(1 piece) Cutting speed : 350 m/min Feed per Tooth : 0.1 mm/tooth Axial Depth of Cut : 0.4 mm Radial Width of Cut : 80 mm Cutting mode : Air blow 6

8 GENERAL PURPOE MULTI CORNER INERT TYPE FACE MILLING CUTTER FACE MILLING <GENERAL CUTTING> Finishing Roughing AHX440 P M K N H Fig. 1 ø40 ø50 ø60 ø80 ON Fig. 2 ø100 ø125 ON KAPR :60 GAMP :-6 GAMF :-5 T :10 (When using the MK breaker insert) T :20 (When using M breaker insert) I : a Heptagonal double sided insert. a Economical 14 cutting edge inserts. a Multi insert design for high feed machining. DAH X Fig. 3 ø160 Right hand tool holder only. CB X ø101.6 ON CB X ø18 Order Number tock Coolant Hole Number of Teeth X ONM DAH CB WT (kg) Tool Holder Number Clamp crew Wrench (Insert) AHX440 TP4R TIP15W Clamp Torque (N m) : TP4R=3.5 (mm) 40 AHX A03AR a u AHX A04AR a u AHX A04AR a u AHX A05AR a u AHX A06AR a u AHX A05AR a u AHX A06AR a u AHX A08AR a u AHX A06AR a u AHX A08AR a u AHX A10AR a u AHX B07AR a u AHX B10AR a u AHX B12AR a u AHX B08AR a u AHX B12AR a u AHX B14AR a u AHX C10NR a AHX C14NR a AHX C14NR a (Note) The cutter body does not have a set bolt for an arbor.please order a et Bolt seperatly. PA PART INERT Type (Fig.) 7 hape Order Number Class Honing Coated MP6120 MP6130 MP7130 MP7140 Dimensions (mm) NNMU130508ZER-L M E a a a a a s NNMU130508ZEN-M M E a a a a a s NNMU130532ZEN-M M E a a a a a s NNMU130532ZEN-R M E a a a a a s When not using the Wiper, = 3.5mm a : Inventory maintained (10 inserts in one case) s : Inventory maintained in Japan. Geometry 5.1

9 P M COMMENDED CUTTING CONDITION vc fz ap Work Material Hardness Grade (m/min) (mm/t.) (mm) MP ( ) 0.3 ( ) < 3 Mild teel <180HB MP ( ) 0.3 ( ) < 3 Carbon teel Alloy teel Pre-Hardened teel Alloy Tool teel Austenitic tainless teel Ferritic and Martensitic tainless teel Two-phase tainless teel Hardened tainless teel HB HB HB <200HB >200HB <200HB >200HB <280HB >280HB MP ( ) 0.3 ( ) < 3 MP ( ) 0.3 ( ) < 3 MP ( ) 0.3 ( ) < 3 MP ( ) 0.3 ( ) < 3 MP ( ) 0.15 ( ) < 1 MP ( ) 0.15 ( ) < 1 MP ( ) 0.2 ( ) < 3 MP ( ) 0.2 ( ) < 3 MP ( ) 0.2 ( ) < 3 MP ( ) 0.2 ( ) < 3 MP ( ) 0.2 ( ) < 3 MP ( ) 0.2 ( ) < 3 MP ( ) 0.2 ( ) < 3 MP ( ) 0.2 ( ) < 3 MP ( ) 0.15 ( ) < 3 MP ( ) 0.15 ( ) < 3 MP ( ) 0.15 ( ) < 3 MP ( ) 0.15 ( ) < 3 K 220 ( ) 0.3 ( ) < Tensile trength 3 Gray Cast Iron <350MPa 180 ( ) 0.3 ( ) < 3 Ductile Cast Iron Ductile Cast Iron Tensile trength <450MPa Tensile trength <800MPa 200 ( ) 0.2 ( ) < ( ) 0.2 ( ) < ( ) 0.2 ( ) < ( ) 0.2 ( ) < 3 H Hardened teel 40 55HRC 80 ( ) 0.15 ( ) < 1 Reduce the cutting speed by 50-60% when using coolant. arevolution(min -1 )=(1000 x Cutting peed vc) (3.14 x ø) atable Feed(mm/min) = Feed per Tooth fz x Number of Teeth x Cutter Revolution OPTIONAL PART LIT et Bolt Tool Holder Number With coolant hole Without coolant hole Type Reference Dimensions (mm) Geometry Order Number Order Number a b c d e f g AHX AooAR HC08025H HC M AHX AooAR HC10030H HC M AHX AooAR HC10030H HC M AHX AooAR HC12035H HC12035 HC M Fig.1 e a d c b AHX BooAR MBA16033H 2 40 M AHX BooAR MBA20040H 2 50 M AHX CooNR No coolant hole 2 50 M Fig.2 a f b g e d c 8

10 GENERAL PURPOE MULTI CORNER INERT TYPE FACE MILLING CUTTER FACE MILLING <GENERAL CUTTING> Finishing Roughing AHX640 P M K N H Fig. 1 ø63 ø80 ON Fig. 2 ø100 ø125 ø160 ON a Heptagonal double sided insert. a Economical 14 cutting edge inserts. a Multi insert design for high feed machining. DAH X Fig. 3 ø200 Right hand tool holder only. CB X ø101.6 ON CB X ø18 Cutter Diameter et Bolt Geometry &63 HC10030H z &80 HC12035H z x &100 MBA16033H &125 MBA20040H x KAPR : T :10 (When using the MK breaker insert) &160 GAMP :-6 T :20 (When using MP, MM breaker inserts) &200 GAMF :-5 I : Dimensions (mm) Order Number R X ON DAH CB (kg) (mm) Clamp crew Wrench AHX A04AR a u C T TKY20T AHX A04AR a u C T TKY20T Type Coarse Pitch Fine Pitch tock Coolant Hole Number of Teeth AHX B05AR a u C T TKY20T AHX B06AR a u C T TKY20T AHX C07NR a C T TKY20T AHX C08NR a C T TKY20T AHX A05AR a u C T TKY20T AHX A06AR a u C T TKY20T AHX B07AR a u C T TKY20T AHX B08AR a u C T TKY20T AHX C10NR a C T TKY20T AHX C12NR a C T TKY20T 1 Clamp Torque (N m) : C T=5.0 WT Type (Fig.) 9 a : Inventory maintained (10 inserts in one case)

11 INERT Type hape Order Number Class Honing Coated MP7030 Dimensions (mm) Geometry MP Breaker NNMU200708ZEN-MP M E a For teel and General use WP Breaker (Wiper) WNEU2007ZEN7C-WP M E a For tainless MM Breaker NNMU200712ZER-MM M E a MK Breaker 1 NNMU200608ZEN-MK M E a a For Cast Iron General HK Breaker 1 trong Cutting Edge Type WK Breaker 1 NNMU200608ZEN-HK M E a a WNEU2006ZEN7C-WK E E a The MK/HK/WK breaker insert is compatible with AHX640W. 2 Possible Wiper combinations:mk/hk with WK (Wiper) & MP with WP (Wiper) 3 Note that the height differs when MK/HK breaker inserts are used. = 10

12 GENERAL PURPOE MULTI CORNER INERT TYPE FACE MILLING CUTTER COMMENDED CUTTING CONDITION y Dry cutting P Mild teel <180HB MP 250 ( ) 0.3 ( ) HB MP 220 ( ) 0.3 ( ) HB MP 140 ( ) 0.3 ( ) 5 M <200HB MM MP ( ) 0.2 ( ) 5 Austenitic tainless teel >200HB MM MP ( ) 0.2 ( ) 5 Duplex teel <280HB MM MP ( ) 0.15 ( ) 5 <200HB MM MP ( ) 0.2 ( ) 5 >200HB MM MP ( ) 0.2 ( ) 5 <450HB MM MP ( ) 0.15 ( ) 5 K MK,HK 220 ( ) 0.3 ( ) Tensile trength 5 Cast Iron <350MPa MP,MK,HK 180 ( ) 0.3 ( ) 5 MK,HK 200 ( ) 0.2 ( ) 5 MP,MK,HK 170 ( ) 0.2 ( ) 5 MK,HK 170 ( ) 0.2 ( ) 5 MP,MK,HK 150 ( ) 0.2 ( ) 5 H Hardened teel 40 55HRC MP 80 (60 100) 0.15 ( ) 3 (Note 1) Recommend wet cutting for good surface fi nishing of stainless steel. (Tool life is short compared to wet cutting.) (Note 2) With low workpiece clamping rigidity or long overhang of the tool, adjust cutting speed and feed to 70 or 80% of the recommended conditions above. y Wet cutting Work Material Hardness Breaker Grade Carbon teel, Alloy teel Ferritic, Martensitic tainless teel PH tainless teel Ductile Cast Iron Tensile trength <450MPa Tensile trength <800MPa Work Material Hardness Insert Grade M <200HB MM MP ( ) 0.15 ( ) 5 Austenitic tainless teel >200HB MM MP (75 125) 0.15 ( ) 5 Duplex teel <280HB MM MP (60 100) 0.10 ( ) 5 Ferritic, Martensitic tainless teel PH tainless teel <200HB MM MP ( ) 0.15 ( ) 5 >200HB MM MP (75 125) 0.15 ( ) 5 <450HB MM MP (50 90) 0.1 ( ) 5 Titanium Alloy MM MP (20 50) 0.15 ( ) 3 Heat Resistant Alloy MM MP (20 50) 0.15 ( ) 3 y Cutting Condition with Wiper insert Cutting peed (m/min) Cutting peed (m/min) Feed per Tooth (mm/tooth) Feed per Tooth (mm/tooth) Axial depth of cut ap (mm) Axial depth of cut ap (mm) (Note 1) With low workpiece clamping rigidity or long overhang of the tool, adjust cutting speed and feed to 70 or 80% of the recommended conditions above. Work Material P Mild teel <180HB MP WP 250 ( ) 0.3 ( ) 0.5 Carbon teel, Alloy teel Hardness Main Insert Grade HB MP WP 220 ( ) 0.3 ( ) HB MP WP 140 ( ) 0.3 ( ) 0.5 K MK,HK WK 320 ( ) 0.3 ( ) 0.5 Cast Iron Tensile trength <350MPa MP WP 220 ( ) 0.3 ( ) 0.5 Ductile Cast Iron Tensile trength <450MPa Tensile trength <800MPa MK,HK WK 250 ( ) 0.2 ( ) 0.5 MP WP 200 ( ) 0.2 ( ) 0.5 MK,HK WK 220 ( ) 0.2 ( ) 0.5 MP WP 170 ( ) 0.2 ( ) 0.5 Heat Resistant Alloy MP WP 40 (20 50) 0.15 ( ) 0.5 H Hardened teel 40 55HRC MP WP 80 (60 100) 0.15 ( ) 0.5 (Note 1) With low workpiece clamping rigidity or long overhang of the tool, adjust cutting speed and feed to 70 or 80% of the recommended conditions above. Wiper Insert Grade Cutting peed (m/min) Feed per Tooth (mm/tooth) Axial depth of cut ap (mm) 11

13 FACE MILLING <HIGH FEED CUTTING FOR CAT IRON> AHX640W P M K N H Finishing Fig.1 ø80 Roughing ON Fig.2 ø100 ø125 ø160 ON KAPR : GAMP :-6 GAMF :-4 T :+10 I : a Heptagonal double sided insert. a Economical 14 cutting edge inserts. a Multi insert design for high feed machining. (T,I : When using the MK breaker insert) Fig.3 ø200 ø250 DAH X ø101.6 ON CB X ø18 CB X Right hand tool holder shown. CB X Fig.4 ø177.8 ø315 ø101.6 ON ø18 ø22 Type Extra Fine Pitch Type uper Extra Fine Pitch Type Order Number tock Number Dimensions(mm) R L of Teeth X ON DAH CB AHX640W-080A08R/L a s AHX640W-100B10R/L a s AHX640W-125B12R/L a s AHX640W-160C16R/L a s AHX640W-200C20R/L a s AHX640W-250C24R/L a s AHX640W-315C28R/L a s AHX640W-080A10R/L a s AHX640W-100B14R/L a s AHX640W-125B18R/L a s AHX640W-160C22R/L a s AHX640W-200C28R/L a s AHX640W-250C36R/L a s AHX640W-315C44R/L a s WT (kg) (mm) Type (Fig.) PA PART Tool Holder Number Wedge Clamp crew Wrench AHX640W CWAHX640WN L0622T TKY15T Clamp Torque (N m) : L0622T=6.0 a : Inventory maintained. s : Inventory maintained in Japan. 12

14 GENERAL PURPOE MULTI CORNER INERT TYPE FACE MILLING CUTTER INERT hape Order Number Class Honing Coated VP20RT Dimensions (mm) Geometry MK Breaker NNMU200608ZEN-MK M E a a a General HK Breaker NNMU200608ZEN-HK M E a a a trong Cutting Edge Type Wiper WNEU2006ZEN7C-WK E E a F1 D1 The inserts can be used with both right and left hand cutters. INERT APPLATION MK HK table Cutting Unstable Cutting y GENERAL CUTTING K COMMENDED CUTTING CONDITION Work Material Gray Cast Iron Ductile Cast Iron Tensile trength <350MPa <450MPa <800MPa Grade VP20RT VP20RT VP20RT Cutting peed (m/min) 220 ( ) 180 ( ) 200 ( ) 170 ( ) 170 ( ) 140 ( ) y FINIHING (UE OF WIPER INERT) Feed per Tooth (mm/tooth) 0.3 ( ) 0.3 ( ) 0.2 ( ) 0.2 ( ) 0.2 ( ) 0.2 ( ) Axial Depth of Cut Cutting peed Work Material Grade (mm) (m/min) 320 K <0.5 Gray ( ) Cast Iron ( ) 270 <0.5 Ductile ( ) Cast Iron ( ) Please use 2-3 pcs of Wiper inserts in case of 'over 6mm/rev'. Feed per Tooth (mm/tooth) 0.2 ( ) 13 a : Inventory maintained (10 inserts in one case)

15 APPLATION EXAMPLE Component Parts for turbo Automobile parts teel plate for pressure containers CH13X FCD500 Workpiece Cutting Conditions Tool AHX A08AR AHX A04AR AHX B10AR Cutting peed (m/min) Feed per Tooth (mm/t.) Axial Depth of cut ap (mm) Radial Depth of cut ae (mm) Cutting mode Dry Dry Wet Results AHX440 achieved 1.4 times the tool life of conventional. AHX440 achieved 1.4 times the tool life of conventional. 160min. could be expanded. The tool life was expanded 160 min in total of rough and fi nish cutting. AHX440 showed 1.3 times longer tool life than that of conventional in heavy interrupted cutting. Tool life was evaluated based on wheather burrs were generated around holes. Component Press mold base Housing case Automotive suspension part FC250 FC250 FCD600 Workpiece Cutting Conditions Tool AHX640WR16016F AHX640WR12512E AHX640WR10014D Cutting peed (m/min) Table Feed (mm/min) Feed per Tooth (mm/t.) Axial Depth of cut ap (mm) Radial Width of cut ae (mm) Cutting mode Dry Dry Dry Results In comparison with the conventional insert that suffered sudden fracturing during machining of surface scale, AHX640W gave a stable performance even at 3 times higher table feeds, thus substantially improving machining effi ciency and reliability. In comparison with a conventional 8 corner insert that fractured while machining an unstable component, the AHX640W gave double tool life. In combination with the use of the extra cutting edges a substantial saving can be made. Even when machining ductile cast irons, AHX640W gave double tool life compared to a conventional tool. a With reference to the above examples, adjust the cutting conditions according to the machine specifi cations, workpiece geometry and clamping method used. 14

16 APPLATION EXAMPLE Component Machine parts Machine parts Mold JI 45C JI CM440 JI KT4 (HRC43) Workpiece Cutting Conditions Tool Conventional AHX640R10007DA Conventional AHX640R10007DA Conventional AHX640R10007DA Cutting peed (m/min) Feed per Tooth (mm/t.) Axial Depth of cut ap (mm) Radial Depth of cut ae (mm) Cutting mode Air blow Air blow Air blow Air blow Air blow Air blow Results With older products, raising the cutting speed to 250 m/min caused chattering and damage to the inserts, but the AHX640 enables stable machining even when the feed is raised. In addition, the inserts have more usable corners, helping to reduce costs. Previously, low rigidity workpiece clamping led to chattering, making it impossible to raise cutting conditions. However, with the low cutting resistance of the AHX640, cutting conditions can be raised, achieving more than six times the efficiency of existing products. With conventional products, insert wear occurred frequently. In contrast, the AHX640 with 30% higher feed enables stable cutting with no damage to the inserts. Component Mold JI FC300 Workpiece Cutting Conditions Tool Conventional AHX640R16010FA Cutting peed (m/min) Feed per Tooth (mm/t.) Axial Depth of cut ap (mm) 1 3 Radial Depth of cut ae (mm) Cutting mode Air blow Air blow Results Compared with earlier tools for high feed milling, depth of cut is three times greater with the equivalent table feed. In addition, the inserts have more usable corners than earlier products, helping to reduce costs. a With reference to the above examples, adjust the cutting conditions according to the machine specifi cations, workpiece geometry and clamping method used. MMC HARTMETALL GmbH Comeniusstr. 2, Meerbusch, Germany Tel Fax admin@mmchg.de MITUBIHI MATERIAL EPAÑA,.A. Calle Emperador 2, Museros/Valencia, pain Tel Fax mme@mmevalencia.com MMC HARDMETAL RUIA OOO LTD. Electozavodskaya tr. 24, build r. Moscow, Russia Tel Fax info@mmc-carbide.ru MMC HARDMETAL U.K. LTD. Mitsubishi House, Galena Close, Tamworth, taffs. B77 4A, U.K. Tel Fax sales@mitsubishicarbide.co.uk MMC ITALIA.r.l. Via Montefeltro 6/A, Milano, Italy Tel Fax info@mmc-italia.it MMC Hartmetall GmbH Almanya - İzmir Merkez Şubesi Adalet Mahallesi Anadolu Caddesi No: 41-1 / Bayraklı/İzmir TURKY Tel Fax info@mmchg.com.tr MMC METAL FRANCE s.a.r.l. 6, Rue Jacques Monod, Orsay, France Tel Fax mmfsales@mmc-metal-france.fr MMC HARDMETAL POLAND P. z o.o. Al..Armii Krajowej 61, Wroclaw, Poland Tel Fax sales@mitsubishicarbide.com.pl EXP-10-E E( - ) Printed in Germany