Chip Thinning Operating Parameters

Transcription

1 Chip Thinning Operating Parameters CHIP THINNING (SLOTTING) CUTTER DIAMETER DEPTH OF CUT DEPTH OF CUT To find the Radial Chip Thinning Factor for a slotting cut:. Find the Depth of Cut on the horizontal scale.. Locate the nominal diameter of the cutter on the vertical axis. 3. Crossreference the two figures. 4. Locate the diagonal line closest to the intersection of the vertical and horizontal axes. The value of this diagonal is the Radial Chip Thinning Factor for your specific application. 5. Multiply this radial chip thinning factor with the calculated chip thickness to get the actual chip thickness CUTTER DIAMETER OPERATING PARAMETERS IN530 IN655 IN05/IN00 Brinell Feed per Material Hardness SFM Insert Coolant IN030 IN040 Grades* IN005 IN5K (Polished) IN70N Aluminum 606T6, 7075T6, Yes Cast Iron Gray Nodular No Low Carbon 08, High Carbon F680, Nitralloy Steel 3 No Alloyed Steel 440, 4340, Tool Steel A6, D, D, P0 Up to Series, 304, May not be Stainless required at 400 Series, 55 PH, 74 PH Up to Steel high speeds 38 PH Yes Nickel Inconel 600, 706, 78, Alloys 903, Hastelloy, Waspalloy Yes Titanium 6AL4V Yes *In order of preference. 7

2 Operating Parameters INSERT SERIES: DPM34/DPM34 IN05 IN040 Grades* Brinell Feed per Material Hardness SFM Insert Coolant IN005 Cast Iron Gray Nodular No Low Carbon 08, Steel High Carbon F680 Nitralloy 500 Alloyed Steel 440, 4340, 650 Tool Steel A6, D, D, P Up to No Stainless Steel 300 Series 304, series, 55 PH, 74 PH Up to May not be required at high speeds 38 PH Yes Nickel Alloys Inconel 600, 706, , Hastelloy, Waspalloy Yes Titanium 6AL4V Yes INSERT SERIES: DPM44/DPM434 IN05 IN040 IN005 IN530 IN655 Grades* Brinell Feed per Material Hardness SFM Insert Coolant Cast Iron Gray Nodular No Low Carbon 08, Steel High Carbon F680 Nitralloy 500 Alloyed Steel 440, 4340, 650 Tool Steel A6, D, D, P Up to No Stainless Steel 300 Series 304, series, 55 PH, 74 PH Up to May not be required at high speeds 38 PH Yes 8 Nickel Alloys Titanium Inconel 600, 706, , Hastelloy, Waspalloy 6AL4V Yes Yes

3 Grade and Carbide Selection CHOOSING A GRADE Grade Material IN05 / IN00 Grey, ductile, nodular iron dry or wet, low to medium cutting speed, low to medium chip thickness. IN655 Grey, ductile, nodular iron dry, medium to high cutting speed, medium to high chip thickness. Heavily interrupted cuts. IN530 General purpose mild steel, hitemp alloys, or stainless steel. Interrupted cuts. Wet. IN030 / IN005 Hitemp alloys. Poor setup rigidity. Wet or dry. IN040 General purpose mild steel and steel alloys, ductile and nodular iron (dry only), when setup rigidity is good. IN654 / IN650 Grey, ductile, nodular iron dry or wet, noninterrupted milling, low to medium cutting speed, medium to high chip thickness. IN5K (w/polish) Nonferrous materials. Wet. IN70N Grey, ductile, nodular iron dry only, very high speed, low to medium chip thickness. CARBIDE SELECTION GUIDE Direction of Use Material New CL Coating Wear Resistance Increase Speed Toughness Increase Feed Short Chipping Malleable Iron, NonFerrous Metal, Hardened Iron, Chilled Iron, Cast Iron C C C3 C4 K50 K45 K40 K35 K30 K5 K0 K5 K0 K05 K0 Wear Resistance Wear Resistance Toughness Toughness Increase Feed Increase Feed Increase Speed Increase Speed HighTemp Alloys, Alloy Free Cutting Steels, Malleable Iron, Iron, Steel Casting, Steel Casting, Steel Manganese C5 C6 C7 C8 M50 M40 M30 M0 M0 P50 P45 P40 P35 P30 P5 P0 P5 P0 P05 P0 IN5K IN650 IN655 IN530 IN005 IN00 IN05 IN030 IN040 N70N Uncoated CVD CVD PVD PVD PVD PVD PVD PVD NonCarbide IN5K IN650 IN655 IN655 IN530 IN530 IN530 IN005 IN005 IN00 IN05 IN05 IN05 IN030 IN030 IN030 IN040 IN70N 9

4 Standard Inserts for Special Steel INSERTS: 0 LEAD RH ONLY.50 DPM34R DPM34R DPM44R Grades Insert Insert Corner Color Code Number IN DPM34R00.03 DPM34R00.03 DPM44R00.03 INSERTS: SLOTTING RH/LH.300 DPM Grades Insert Insert Corner Color Code Number IN DPM DPM

5 General Application Information APPLYING BASIC PRINCIPLES OF MACHINING WITH INDEXABLES CAN IMPROVE PERFORMANCE The following information is directed toward indexable carbide tools but it can be applied to many other cutting tools, as well. It provides some basic guidelines designed to serve as a starting point for safe and reliable performance. Contact your Ingersoll Cutting Tool Company sales engineer or distributor for specific application assistance. Rigidity. Use the most rigid cutter possible. This usually means the cutter with the largest diameter and shortest length. Use the best adaption possible. Integral tapers, such as a 50 Vflange, are better than straight shanks. When selecting straight shank tools, use a cutter with the largest diameter shank possible and a holder with the shortest length possible. Effective cutting edges. When calculating feed rate, use the effective number of inserts. In extended flute cutters, the effective number of inserts is not the number of rows. Use the effective number listed with the specifications for each series of tools. Chip load. Carbide cutting tools have to take a bite to cut. Be sure to cut with an adequate chip load. Light chip loads can contribute to chatter, causing a cutter to rub instead of bite. This can also result in poor tool life. As a general rule, chip loads should not be less than.004". Also, be sure to use Radial Chip Thinning Factors (RCTF) when calculating feed rates. Chip recutting. Unlike HSS, carbide cutting tools cannot recut chips. Recutting chips will damage carbide. To evacuate chips, use air or coolant depending on the material being cut. Coolant. Generous amounts of coolant are required when low thermal conductivity, work hardening, and chip welding tendencies are evident. Use coolant only when necessary. Some materials cut better dry. In some applications, coolant causes thermal cracking of inserts and poor tool life. Feed rates. Reduce feed rates by 50 percent when entering or exiting a cut. Since fewer inserts are engaged in the work, pounding can occur. Reducing feed rates will reduce the shock of the interrupted cut and contribute to longer tool life. When entering a corner during pocket milling, a larger portion of the cutter s diameter is engaged. Power requirements and tool deflection increase. To compensate, program a reduced interpolated feed rate. Alternately, drill or plunge the corner prior to milling. Cutter rotation. Climb cut whenever possible. Carbide is designed for climb milling and will not generally perform as well when conventional cutting. Conventional cutting may be employed on older machines to minimize backlash. It can also extend tool life in sandy, scaly, or torchcut surfaces as the cutting edge enters into cleaner, softer material. Feed Feed Feed Entering a Cut Exiting a Cut Corner Cutting Reduce feed rates by 50% when entering a cut, exiting a cut, or entering a corner. This reduces pounding and cutting forces and can extend the life of your indexable carbide tool. 3

6 Standard Milling Formulas Surface Speed per Minute SFM =.6 x Diameter x RPM Revolutions per Minute Feed per Revolution RPM = 3.8 x SFM Diameter FPR = IPM RPM Inches per Minute Feed per Insert IPM = RPM x FPR FPI = FPR No. Eff. Insert Horsepower equals Material Removal Rate divided by the "K" Factor HP = Horsepower WOC x DOC x IPM K 3 Material Aluminum BrassSoft BrassHard BronzeHard BronzeVH Cast Iron 00 Bhn Cast Iron > 00 Bhn Steel 00 Bhn Steel 50 Bhn Steel 00 Bhn Steel 50 Bhn Steel 400 Bhn Stainless Steel High Temp Alloys "K" Factors ,

7 MODIFIED STANDARDS AND SPECIALS PRODUCT WORKSHEETS APPENDIX 33

8 appendix product worksheet suggested diameter VARIABLE FEATURES A: SLOTTING/SLABBING AND TSLOTTING B: C: D: E: F: G: H: APPLICATION DATA WORKPIECE MATERIAL AVG. RADIAL DOC RPM FEED RATE MACHINE TYPE MACHINE H.P. MAX. TOOL ASSY. WEIGHT 34 MEASUREMENT UNITS USED INCH MM THIS PAGE MAY BE COPIED AND VARIABLES FILLED IN TO COMMUNICATE BASIC DESIGN REQUIREMENTS REMARKS

9 appendix product worksheet suggested diameter.00 + VARIABLE FEATURES HEAVYDUTY SHELL MILL A: B: Coolant thru: yes no C: D: E: F: G: APPLICATION DATA WORKPIECE MATERIAL AVG. RADIAL DOC RPM FEED RATE MACHINE TYPE MACHINE H.P. MAX. TOOL ASSY. WEIGHT MEASUREMENT UNITS USED INCH MM THIS PAGE MAY BE COPIED AND VARIABLES FILLED IN TO COMMUNICATE BASIC DESIGN REQUIREMENTS REMARKS 35

10 appendix product worksheet suggested diameter.50 + VARIABLE FEATURES A: B: C: D: E: HEAVYDUTY ENDMILLING Coolant thru: yes no Adaption style: APPLICATION DATA WORKPIECE MATERIAL AVG. RADIAL DOC RPM FEED RATE MACHINE TYPE MACHINE H.P. MAX. TOOL ASSY. WEIGHT 36 MEASUREMENT UNITS USED INCH MM THIS PAGE MAY BE COPIED AND VARIABLES FILLED IN TO COMMUNICATE BASIC DESIGN REQUIREMENTS REMARKS

11 appendix product worksheet Optional PA063 Anvil VARIABLE FEATURES A: B: C: D: E: F: G: H: I: J: MEASUREMENT UNITS USED INCH MM THIS PAGE MAY BE COPIED AND VARIABLES FILLED IN TO COMMUNICATE BASIC DESIGN REQUIREMENTS APPLICATION DATA WORKPIECE MATERIAL AVG. AXIAL DOC RPM FEED RATE STRADDLE MILLING FULL SIDE MILLING Cutter # quantity of inserts: Cutter # quantity of inserts: Adaption style: MACHINE TYPE MACHINE H.P. MAX. TOOL ASSY. WEIGHT REMARKS 37

12 appendix product worksheet VARIABLE FEATURES A: B: C: D: E: F: COMBINATION FINISH FACE MILL Proposed quantity of rougher inserts: Proposed quantity of finisher inserts: Rougher lnest protection/ adjustment requested: yes Coolant manifold requested:..yes APPLICATION DATA WORKPIECE MATERIAL AVG. AXIAL DOC no no RPM FEED RATE MACHINE TYPE MACHINE H.P. MAX. TOOL ASSY. WEIGHT REMARKS 38 MEASUREMENT UNITS USED INCH MM THIS PAGE MAY BE COPIED AND VARIABLES FILLED IN TO COMMUNICATE BASIC DESIGN REQUIREMENTS

13 appendix product worksheet optional PAR065/PAL065 nest suggested diameter.50 + VARIABLE FEATURES A: B: C: D: E: BORING quantity of inserts: Adaption style: Coolant thru: yes no Lnest pocket protection/ adjustment requested yes no APPLICATION DATA WORKPIECE MATERIAL AVG. RADIAL DOC RPM FEED RATE MACHINE TYPE MACHINE H.P. MAX. TOOL ASSY. WEIGHT REMARKS MEASUREMENT UNITS USED INCH MM 39 THIS PAGE MAY BE COPIED AND VARIABLES FILLED IN TO COMMUNICATE BASIC DESIGN REQUIREMENTS

14 Ingersoll Cutting Tools for the Americas Ingersoll Cutting Tools for Europe Marketing & Technology Center Marketing & Technology Center 845 S. Lyford Road Ingersoll Werkzeuge GmbH Rockford, IL U.S.A. KalteicheRing Haiger, Germany Tel: Fax: Tel: info@ingersollimc.com Fax: /84 Internet: info@ingersollimc.de Internet: Ingersoll Cutting Tool Ltd. 450 Rhodes Drive, Unit #00 Windsor, Ontario N8W 5K5, Canada Tel: Fax: Ingersoll Cutting Tools de México S.A. de C.V. Carr. Saltillo Monterrey Km. 5.5, Local y 3 Saltillo, Coahuila C.P. 500, México Tel: (844) , (844) Fax: (844) CAT008 (05)