Highest cutting rates and tool life thanks to the application of Guhring solid carbide threading tools in steels, cast iron and aluminium alloys

Transcription

1 SOLID carbide threading tools application examples for optimising your Production: Highest cutting rates and tool life thanks to the application of Guhring solid carbide threading tools in steels, cast iron and aluminium alloys

2 Solid carbide threading tools - especially taps and fluteless taps - continue to be regarded with scepticism by many users. They primarily fear tool breakage when maching steel due to the low toughness of the carbide. Only for machining aluminium and cast iron solid carbide taps and fluteless taps have been able to conquer a small niche. Completely unjustified as the following application examples of solid carbide taps, fluteless taps and thread milling cutters in the most diverse materials attest! Highly efficient production of threads with solid carbide Guhring is setting new standards for many application tasks with its solid carbide threading tools. In particular their specially adapted carbide grades in order to satisfy the requirements of thread production with taps, fluteless taps and thread milling cutters allow Guhring s solid carbide threading tools to achieve highest cutting speeds and tool life. Such special carbide grades allow thread cutting tools to be applied at high speed without tool breakage, whilst at the same time the hardness of the high-tech carbide is preserved. As well as the carbide grades, the tool geometries and the coatings are also adapted to the individual field of application. This fine adjustment of all tool characteristics is possible thanks to pooling all expertise in matters tool production within the Guhring group. As probably the only tool manufacturer world-wide, Guhring has its own carbide development and production, its own research and development centre for tool geometries, its own coating technology division for developing coatings and coating systems as well as its own machine division that develops and produces the necessary machines and systems for the production of innovative tools. 2

3 Taps solid carbide Guhring no. Dimension to Tool Tolerance zone Thread type Type/Form Surface finish Cooling 942 ~ DIN 371 6HX M N/B TiN without 943 ~ DIN 371 6HX MF N/B TiN without 969 DIN 371 6HX M H/C bright axial 1008 DIN 371 6HX M H/E bright axial 1858 DIN 371 6HX M H/C bright radial 2311 DIN 371 6HX M H/C radial 2506 DIN 371 6HX M H/C axial 971 DIN 371 6HX M N R15/C bright axial 2516 DIN 371 6HX M N R15/C MolyGlide axial 2510 DIN 371 6HX M N R15/C axial 972 DIN 371 6HX MF H/C bright axial 1009 DIN 371 6HX MF H/E bright axial 1861 DIN 371 6HX MF H/C bright radial 975 DIN 371 6HX MF N L15/D bright radial 977 DIN 371 6HX MF N R15/C bright axial 974 DIN 374 6HX MF H/C bright axial 1860 DIN 374 6HX MF H/C bright radial 976 DIN 374 6HX MF N L15/D bright radial 978 DIN 374 6HX MF N R15/C bright axial 944 DIN 374 6HX MF N/B TiN without 1859 DIN 376 6HX M H/C bright radial 1883 DIN 376 6HX M H/C bright axial Guhring standard Guhring standard ISO2/6H M H/D TiCN without ISO2/6H MF H/D TiCN without 3

4 Thread milling cutters solid carbide Type Thread type Tool Length Surface finish Cooling Guhring no. DTMC SP M 1,5 x D / 2 x D / 2,5 x D bright / TiCN without / axial 3774, 3775, 3776, 3777, 3778, 3779, 3780, 3781, 3782, 3783, 3784, 3785 DTMC SP MF 1,5 x D / 2 x D / 2,5 x D bright / TiCN without / axial 3786, 3787, 3788, 3789, 3790, 3791, 3792, 3793, 3794, 3795, 3796, 3797 TM SP M 2 x D / 2,5 x D TM SP G 2 x D / 2,5 x D axial 3734, 3735, 3737, 3740, 3743, 3744 axial 3745, 3746, 3748, 3750, 3751, 3752 TM SP NPT axial 3753, 3754, 3755, TM SP NPTF axial 3756, 3757, 3758 TMC SP M 1,5 x D / 2 x D / 2,5 x D axial 3510, 3511, 3525, 3526, 3543, 3544, 3759, 3760, 3761 TMC SP MF 1,5 x D / 2 x D / 2,5 x D axial 3512, 3513, 3527, 3528, 3545, 3546, 3762, 3763, 3764 TMC SP UNC 1,5 x D / 2 x D TMC SP UNF 1,5 x D / 2 x D axial 3516, 3517, 3534, 3535, 3549, 3550 axial 3518, 3519, 3536, 3537, 3551, 3552 TMC SP G 1,5 x D / 2 x D / 2,5 x D axial 3514, 3515, 3529, 3533, 3547, 3548, 3765, 3766, 3767 TMC SP NPT axial 3520, 3538, 3553 TMC SP NPTF axial 3521, 3539, 3554 TMU SP M/MF axial 3523, 3541, 3556 TMU SP UNC/ UNF axial 3595, 3596, 3597 TMU SP G axial 3524, 3542, 3557 TMU SP NPT axial 3768, 3769, 3770 TMU SP NPTF axial 3771, 3772,

5 Fluteless taps solid carbide Guhring no. Dimension to Tool Tolerance zone Thread type Type/form Surface finish Cooling 1972 ~ DIN 371 6HX M N/C TiCN radial 2518 ~ DIN 371 6HX M N/C TiN axial 1927 ~ DIN 371 6HX M N/E TiCN radial 1581 ~ DIN 374 6HX MF N/C TiCN radial 1931 ~ DIN 376 6HX M N/C TiCN radial 5

6 Solid carbide taps: Steel flange Workpiece: flange Material: C45 Thread: M8 Thread depth: 16 mm Thread type: through hole Tool holder: HSK 63 - synchro chuck Lubrication: soluble oil 8% Previous tool: HSS-E, TiN-coated Cutting speed: 12 m/min Tool life: 1000 threads New tool: solid carbide, TiN-coated, Guhring no. 942 Cutting speed: 50 m/min Tool life: 8000 threads Cutting speed: % Tool life: % Solid carbide taps: Steel con rod Workpiece: con rod Material: C 70 Thread: M9x1.25 Thread depth: 15 mm Thread type: through hole Tool holder: HSK 63 - synchro chuck Lubrication: soluble oil 8% Previous tool: PM-HSS-E, TiCN-coated Cutting speed: 15 m/min Tool life: 1400 threads New tool: solid carbide, TiCN-coated, sim. to Guh. no. 944 Cutting speed: 50 m/min Tool life: 9000 threads Cutting speed: % Tool life: % 6

7 Solid carbide taps: Steel housing Workpiece: housing Material: St 52 Thread: M10 Thread depth: 18 mm Thread type: through hole Tool holder: SK 40 - synchro chuck Lubrication: soluble oil 6% Previous tool: HSS-E, TiN-coated Cutting speed: 10 m/min Tool life: 1000 threads New tool: solid carbide, TiN-coated, Guhring no. 942 Cutting speed: 50 m/min Tool life: 8000 threads Cutting speed: % Tool life: % Solid carbide taps: Steel flanged shaft Workpiece: flanged shaft Material: Cf 53 Thread: M14x1.5 Thread depth: 22 mm Thread type: through hole Tool holder: HSK 63 - synchro chuck Lubrication: soluble oil 8% Previous tool: HSS-E, TiN-coated Cutting speed: 10 m/min Tool life: 1250 threads New tool: solid carbide, TiN-coated, Guhring no. 944 Cutting speed: 50 m/min Tool life: threads Cutting speed: % Tool life: % 7

8 Solid carbide taps: Cast iron crankshaft Workpiece: crankshaft Material: GGG 70 Thread: M16 x 1.5 Thread depth: 30 mm Thread type: blind hole Tool holder: HSK 63 rigid in collet Lubrication: soluble oil 8%, axial IC Previous tool: HSS-E, TiCN-coated, axial IC Cutting speed: 20 m/min Tool life: 6000 threads New tool: solid carbide, TiCN-coated, radial IC, Guh. no Cutting speed: 40 m/min Tool life: threads Cutting speed: % Tool life: % Solid carbide taps: CGI crankcase Workpiece: crankcase Material: CGI 450 Thread: M10 Thread depth: 25 mm Thread type: blind hole Tool holder: rigid in collet Lubrication: soluble oil 10%, axial IC Previous tool: HSS-E PM, -coated, axial IC Cutting speed: 18 m/min Tool life: 6000 threads New tool: solid carbide, -coated, axial IC Cutting speed: 40 m/min Tool life: threads Cutting speed: % Tool life: % 8

9 Solid carbide taps: Aluminium silicon casing Workpiece: casing Material: AlSi7 Thread: M10 Thread depth: 25 mm Thread type: blind hole Tool holder: rigid in collet Lubrication: soluble oil 10%, axial IC Previous tool: HSS-E PM, -coated, axial IC Cutting speed: 25 m/min Tool life: threads New tool: solid carbide, -coated, axial IC, Guh. no Cutting speed: 50 m/min Tool life: threads Cutting speed: % Tool life: % Solid carbide taps: Aluminium silicon cylinder head Workpiece: cylinder head Material: AlSi17 Thread: M6 Thread depth: 15 mm Thread type: blind hole Tool holder: synchro chuck in collet Lubrication: soluble oil 9%, axial IC Previous tool: HSS-E PM, -coated, axial IC Cutting speed: 15 m/min Tool life: 8000 threads New tool: solid carbide, -coated, axial IC Cutting speed: 35 m/min Tool life: threads Cutting speed: % Tool life: % 9

10 Solid carbide fluteless taps: Steel axle carrier Workpiece: axle carrier Material: 41Cr54 (1100 N/mm²) Thread: M22x1.5 Thread depth: 45 mm Thread type: blind hole Tool holder: HSK synchro chuck Lubrication: soluble oil 8%, 20 bar, IC Previous tool: HSS-E, TiN-coated, IC Cutting speed: 15 m/min Tool life: 900 threads New tool: solid carbide, TiN-coated, IC, sim. to Guh. no Cutting speed: 30 m/min Tool life: 6000 threads Cutting speed: % Tool life: % Solid carbide fluteless taps: Steel con rod Workpiece: con rod Material: C70 S6 By Thread: M12x1.25 Thread depth: 24 mm Thread type: blind hole Machine: thread cutting machine Tool holder: HSK 63 - synchro chuck Lubrication: oil, 70 bar, IC Previous tool: HSS-E PM, TiN-coated, IC Cutting speed: 15 m/min Tool life: 3000 threads New tool : solid carbide, TiN-coated, IC, sim. to Guh. no Cutting speed: 30 m/min Tool life: threads Cutting speed: % Tool life: % 10

11 Solid carbide fluteless taps: Steel shaft Workpiece: shaft Material: 42 CrMo4 (1200 N/mm2) Thread: M16x1.5 Thread depth: 35 mm Thread type: blind hole Tool holder: HSK 63 - synchro chuck Lubrication: soluble oil 9%, 20 bar, IC Previous tool: HSS-E, TiCN-coated, IC Cutting speed: 12 m/min Tool life: 1200 threads New tool: solid carbide, TiCN-coated, IC, Guh. no Cutting speed: 25 m/min Tool life: 8000 threads Cutting speed: % Tool life: % Solid carbide fluteless taps: Steel crankshaft Workpiece: crankshaft Material: C 38 Thread: M12x1.5 Thread depth: 20 mm Thread type: blind hole Machine: transfer line Tool holder: length compensation chuck Lubrication: soluble oil 8%, 20 bar, IC Previous tool: HSS-E, TiCN-coated, IC Cutting speed: 10 m/min Tool life: 3000 threads New tool: solid carbide, TiCN-coated, IC, Guh. no Cutting speed: 20 m/min Tool life: threads Cutting speed: % Tool life: % 11

12 Solid carbide thread milling cutters: Steel rail Workpiece: rail Material: 38MnSi5 Thread: M18x1.5, M20x1.5 Thread depth: 20 mm Tool holder: shrink fit chuck Lubrication: soluble oil 8%, axial IC Tool: Thread milling cutter D14xM1.5, solid carbide, TiCNcoated, axial IC Cutting speed: 90 m/min Feed rate per tooth: 0.09 mm Tool life: 3000 threads Solid carbide thread milling cutters: Aluminium silicon hydraulic manifold Workpiece: hydraulic manifold Material: AlSi7 Thread: M16x1.5, M22x1.5, M26x1.5 Thread depth: 20 mm Tool holder: whistle notch HE Lubrication: souble oil 9%, axial IC Tool: Thread milling cutter TMU D12xM1.5, solid carbide, bright, axial IC, Guhring no Cutting speed: 200 m/min Feed rate per tooth: 0.12 mm Tool life: threads 12

13 Solid carbide thread milling cutters: Steel balance shaft Workpiece: balance shaft Material: 16 MnCr5 Thread: M10 Thread depth: 20 mm Tool holder: shrink fit chuck Lubrication: soluble oil 6%, axial IC Tool: Thread milling cutter TMC M10 2xD, solid carbide, TiCNcoated, axial IC, similar to Guh. no Cutting speed: 100 m/min Feed rate per tooth: 0.07 mm Tool life: 6000 threads Solid carbide drill/thread milling cutters: Aluminium silicon housing Workpiece: transmission housing Material: AlSi9 Thread: M22x1.5 Thread depth: 20 mm Thread type: through hole with cylindrical step, chamfer and back chamfer Tool holder: whistle notch HE Lubrication: soluble oil 9%, axial IC Tool: Step drill/thread milling cutter M22x1.5, solid carbide, bright, axial IC Cutting speed: 300 m/min Feed rate F (drilling): 0.2 mm/rev. Feed rate per tooth (thread milling): 0.12 mm Tool life: threads 13

14 General information Basic characteristics of carbide for drilling applications For drilling applications the following characteristics are of importance: Rigidity Rigidity is a measure of the energy that is required to force a material to deform. With carbide it is determined by the cobalt content. The higher the cobalt content, the lower the rigidity of the material. High cobalt content and/or coarse hard material grains are an indication of tough carbide. High toughness is required when a sudden or high cutting load occurs during the machining process. A high cutting load arises when there is a high friction coefficient between tool and workpiece. The coefficient of friction is determined by the surface roughness of the tool and by the chemical relationship between the tool surface and the workpiece. The rigidity of conventional carbide is more than double compared to that of steel. Subsequently, holes of considerably greater straightness can be produced with carbide drills than with steel drills. However, this positive effect of the rigidity is limited because of deformation forced upon the drill for example through offset or imbalance result in a heavy increase in load on the material. Therefore, more rigid materials are also more prone to breakage. Hardness Hardness is described as the resistance of a material against penetration of another. It is clear, that the tool material must be considerably harder than that of the workpiece, in order to not be exposed to excessive wear. There are several possibilities to adjust the hardness of carbide: on the one hand by modifying the cobalt content and on the other hand by varying the carbide grain size. If the cobalt content is increased whilst retaining the same grain size, the hardness of the carbide is reduced. However, if the grain size is reduced whilst retaining the same cobalt content, the hardness is increased. Hardness Hardness HV K IC , , , , , , ,4 Grain size in µm Toughness KIC MPam 0,5 Please note, toughness is not synonymous with high bending strength. An important and specific characteristic for determining the bending strength is the cutting edge stability. Cutting edge stability Cutting edge stability is defined as the resistance of the cutting edge against the breakaway of individual hard material grains or larger grain formations. The bending strength provides a rough measure of the cutting edge stability. In addition to toughness, the size of the longest grain boundary within the structure of the material is also of importance for the bending strength. Subsequently, high toughness increases the bending strength, however, longer grain boundaries (= coarser grains) lowers it. Reaction Although today most carbide tools are coated, the reaction tendency between carbide and workpiece must be taken into consideration. Because of rapid wear of the coating at the cutting edge, a reaction between tool and workpiece is indeed a possibility. Similar to pitting in the corrosion process, a localised attack can have a considerably longer lasting effect than any damage over a large area. Due to the high temperature development at the cutting edge, cobalt in particular reacts very quickly with ferrous metals. Other metals, such as titanium or silicon are prone to react with tungsten carbide. For these reasons, the cobalt content is of interest regarding the reaction of the tool. Material selection Dependent on the specific application task, the various attributes must, therefore, be carefully balanced. Subsequently, there are various carbides available. In order to find the correct carbide for a specific application task, several classification systems were experimented with and introduced as standard to simplify the selection. Widely accepted is the DIN ISO classification system to DIN ISO 513. Toughness Toughness is defined as the resistance the material offers against the growth of a fissure. A high fissure resistance is an indication of good-natured carbide, possessing high impact resistance. Unfortunately, hardness and toughness are opposing attributes. Descriptions to DIN ISO 513 are currently used in Germany. This standard can be described briefly as follows. 14

15 General information Surface refining processes, Coatings bright Due to their basically good properties, high speed steel and carbide tools are supplied without being surface treated, i.e. in a bright finish. ideally suited for difficult to machine aerospace materials such as titanium alloys, Inconel as well as machining hardened steel materials (>52 HRC) and HSC applications. Surface refining processes For special applications it is desirable to increase the durability and to reduce the sliding resistance and tendency of cold welding by special surface refining processes. The following refining processes continue to be of less importance. Generally, much better results are achieved with hard or soft coated tools. steam nitrided nitrided lands Nitriding is a further means of increasing the durability of tools. This finish is recommended for the machining of grey cast iron, aluminium with a high silicon content, plastics, steels with a high perlite content etc. Our tools are nitrided using different application orientated processes. C-coat or TiCN-coat Coating colour: grey End mills and taps exposed to high mechanical load are coated with TiCN. With respect to the high hardness and toughness of TiCN coating the tools offer good machining results operating with interrupted cutting. F-coat or FIRE-coat Coating colour: violet This /TiN multilayer coating is applied to HSS and carbide drills. It offers outstanding wear resistance in drilling operations and high heat resistance. Besides conventional wet applications this coating is suitable for minimum lubrication and dry machining, often combined with MolyGlide to optimize the running-in wear and improved resistance to galling. steam tempered Steam tempered tools also offer a reduction in sliding resistance. Thus cold welding which occurs for example during the machining of steels that have a low carbon content, can be avoided most economically. Steam tempered tools are only suitable for ferrous materials. P-coat or AlCrN-coat Coating colour: metallic grey The coating is specially adapted to satisfy the demands of fluteless tapping. Our P-coat based on aluminium chromium nitride (AlCrN) possesses an extremely high oxidation resistance and temperature (red) hardness. The result is a high wear resistance and productivity, as P-coated fluteless taps can be operated with increased cutting parameters and optimally utilise the potential of modern machines. Guhring coatings A-coat or -coat Coating colour: violet The monolayer coating is suited for abrasive operations with carbide tools because of its high hardness and chemical resistance, e.g. hard machining and high speed cutting (HSC). S-coat or TiN-coat Coating colour: yellow-golden The monolayer Titanium Nitride coating is standard for HSS and carbide tools. Used for drilling, tapping and milling operations. Nevertheless, most application is steel machining. Super A-coat or AlTiN-coat Coating colour: grey-violet The well established A-coating has been developed at Guhring. By optimizing the structural, chemical and mechanical properties of the new Super-A coating an extremely high hot hardness, very good oxidation resistance and excellent coating adhesion have been achieved. This coating is used exclusively on carbide cutting tools and is M-coat or MolyGlide -coat Coating colour: light grey MolyGlide is a thin, friction minimizing coating for applications requiring a minimum friction coefficient, e.g. dry or minimum quantity lubrication (MQL) machining. Moreover, this coating offers resistance to galling, when minimum lubrication fails. 15

16 Guhring ohg P.O. Box D Albstadt Herderstr D Albstadt Telephone: Fax: Our product range: 1. Drilling Tools in High Speed Steel and Carbide Twist drills Ratio drills Micro-precision drills Oil feed drills Subland drills Centre drills Core drills Gun drills Drilling systems with interchangeable inserts 2. Thread Cutting Tools in High Speed Steel and Carbide Machine taps and fluteless taps Oil feed taps and oil feed fluteless taps Hand taps Thread milling cutters Dies 3. Milling Cutters in High Speed Steel and Carbide Ratio end mills Slot drills End mills Radius profile cutters Hard profile cutters Diesinking cutters 4. Reaming Tools in High Speed Steel and Carbide NC machine chucking reamers Machine and machine chucking reamers Taper pin reamers Hand reamers 5. Countersinking Tools in High Speed Steel and Carbide Countersinks, counterbores and spot facers Short counterbores, back spot facers De-burring tools 6. Cutting Tools in ultra-hard materials Face milling cutter PF 1000 Cermet and ceramic tools PCD- and PCB-tipped tools 7. Coated Tools A-tools, -coated SuperA-tools, AlTiN-coated C-tools, TiCN-coated F-tools, FIRE-coated (allround) P-tools, AlCrNN-coated S-tools, TiN-coated (allround) M-tools, MolyGlide-coated 8. Modular Tooling Systems Tooling system GM 300 Tool holders, clamping systems and accessories to ISO 12164, DIN and DIN for transfer lines, machining and turning centres Flexible tooling system GE 100 a tooling system for the combined machining operations facing, chamfering, boring, centering etc. ISO indexable inserts, short clamping holders and KV 400 cartridges 9. Special Tools to sketch or drawing, the more complex, the better 10. Carbides for precision cutting tools 11. Carbide Special Parts for the forming, machining and wear protection industry Cold heading dies, ribbed rolls, dies, mandrels, drawing dies, gear cutters, etc. 12. Tool Restoration Service Re-grinding, re-coating, tool management /1008-I-05 Printed in Germany No liability can be accepted for printing errors or technical changes of any kind. Our Conditions of Sale and Terms of Payment apply. Available on request.