BROACHING on CNC machines

Transcription

1 BOACHING on CNC machines BOACHING TOOLS TYPE SB105, SB110 and SH117 For direct mounting in lathes and mills as well as mounting in a live broaching attachment from the companies: - BENZ - EWS - Schwarzer HON 1

2 HCG - HON Catalog Guide KEYWAY BOACHING Keyway Width Inch.236''.354".551".625".669".866" 1.181" 1.496" 1.496" 1/16 NU105 3/32 NU105 1/8 NU105 SU117 SU117 5/32 NU105 NU110 SU117 SU117 3/16 NU110 SU117 SU117 1/4 SU117 9/32 SU117 5/16 SU117 3/8 SU117 7/16 SU117 1/2 SU117 > 1/2 SU117 Keyway Width MM 6 mm 6.5 mm 9 mm 14 mm 17 mm 22 mm 27 mm 30 mm 38 mm 65 mm 2.0 N N105 S N105 N110 S N110 S117 S S S S S S117 > 12.0 S117 HEXAGON BOACHING TOX BOACHING Hexagon SW MM Pilot Ø equals SW SW+0.1 SW N N N N N N N N N N110 Torx MM T15 T20 T25 T30 Pilot Ø equals N105 N105 N105 N105 Special tools upon request

3 SUMMAY BOACHING 105 / 110 / 117 Toolholder Type 105 / 110 Page 4-8 Page Insert Keyway Chamfer Hexagon Torx Type 105 / 110 Page Page 18 Page 19 Page 20 Toolholder Type 117 Page Keyway Chamfer Insert Type 117 Page Page 32 Technical Instructions Page HON 3

4 BOACHING TOOLHOLDE Type SBU for use with Insert Type N105 NU105 Part number d l 1 l 2 D min SBU SBU Further sizes upon request Dimensions in inch Spare parts Toolholder Screw TOX PLUS Wrench SBU T15P T15PQ HON

5 BOACHING TOOLHOLDE Type SB (6.0 mm) for use with Insert Type N105 NU105 Part number d l 1 l 2 D min SB SB SB Further sizes upon request Spare parts Toolholder Screw TOX PLUS Wrench SB T15P T15PQ HON 5

6 BOACHING TOOLHOLDE Type SB (6.0 mm) only usable for broaching devices EWS-Slot and BENZ LinA for use with Insert Type N105 NU105 Part number d l 1 l 2 D min SB E Further sizes for other device interfaces upon request Spare parts Toolholder Screw TOX PLUS Wrench SB E T15P T15PQ HON

7 BOACHING TOOLHOLDE Type B (6.0 mm) for broaching device Schwarzer for use with Insert Type N105 NU105 Part number d l 1 l 2 D min B Further sizes for other device interfaces upon request Spare parts Toolholder Screw TOX PLUS Wrench B T15P T15PQ HON 7

8 BOACHING TOOLHOLDE Type SB (6.0 mm) for broaching device Schwarzer "2in1" for use with Insert Type N105 NU105 Part number d l 1 l 2 D min SB S Further sizes for other device interfaces upon request Spare parts Toolholder Screw TOX PLUS Wrench SB S T15P T15PQ HON

9 BOACHING UPON EQUEST External serration broaching for finish machining on CNC turning machines. Machine MUST have C-Axis for this application! HON 9

10 BOACHING TOOLHOLDE Type SBU for use with Insert Type N110 NU110 Part number d l 1 l 2 D min SBU SBU SBU Further sizes upon request Dimensions in inch Spare parts Toolholder Screw TOX PLUS Wrench SBU T15P T15PQ HON

11 BOACHING TOOLHOLDE Type SB (9.0 mm) for use with Insert Type N110 NU110 Part number d l 1 l 2 D min SB SB SB Further sizes upon request Spare parts Toolholder Screw TOX PLUS Wrench SB T15P T15PQ HON 11

12 BOACHING TOOLHOLDE Type SB (9.0 mm) only usable for broaching devices EWS-Slot and BENZ LinA for use with Insert Type N110 NU110 Part number d l 1 l 2 D min SB E Further sizes for other device interfaces upon request Spare parts Toolholder Screw TOX PLUS Wrench SB E T15P T15PQ HON

13 BOACHING TOOLHOLDE Type SB (9.0 mm) for broaching device Schwarzer "2in1" for use with Insert Type N110 NU110 Part number d l 1 l 2 D min SB S Further sizes for other device interfaces upon request Spare parts Toolholder Screw TOX PLUS Wrench SB S T15P T15PQ HON 13

14 BOACHING THIS PAGE HAS BEEN ELECTONICALLY MODIFIED INSET type NU105/NU '' (6.0 mm) for use with Toolholder type SB105 SB110 SBU105 SBU110 Keyways according to Inch Standards Part number Fractional size w r l 5 l 2 l 3 D min NU /16'' NU /32'' NU /8'' NU /32'' NU /32'' NU /32'' NU /16'' Toolholder SB105 SBU105 SB110 SBU110 NU /16'' on stock Δ 4 weeks P main recommendation M ο alternative recommendation K uncoatet grades S coatet grades N brazed/cermet H MG12 TA45 TI25 Carbide Grades HON

15 BOACHING INSET type N105/N110 Tolerance grade P9.236" (6.0 mm) for use with Toolholder type SB105 SB110 SBU105 SBU110 Keyways according to DIN138 Part number Dimensions of groove DIN Width P9 D min t w r l 5 l 2 l 3 N N N N N N usable from Ø Toolholder SB105 / SBU105 SB110 / SBU110 N on stock Δ 4 weeks P main recommendation M ο alternative recommendation K uncoatet grades S coatet grades N brazed/cermet H MG12 TA45 TI25 Carbide Grades HON 15

16 BOACHING INSET type N105/N110 Tolerance grade JS9.236" (6.0 mm) for use with Toolholder type SB105 SB110 SBU105 SBU110 Keyways according to DIN138 Part number Dimensions of groove DIN Width JS9 D min t w r l 5 l 2 l 3 usable from Ø Toolholder MG12 TA45 TI25 N SB105 / SBU105 N N N N N N SB110 / SBU110 N on stock Δ 4 weeks P main recommendation M ο alternative recommendation K uncoatet grades S coatet grades N brazed/cermet H Carbide Grades HON

17 BOACHING INSET type N105/N110 Tolerance grade C11.236" (6.0 mm) for use with Toolholder type SB105 SB110 SBU105 SBU110 Keyways according to DIN138 Part number Dimensions of groove DIN Width C11 D min t w r l 5 l 2 l 3 N N N usable from Ø Toolholder SB105 / SBU105 N N N N SB110 / SBU110 N on stock Δ 4 weeks P main recommendation M ο alternative recommendation K uncoatet grades S coatet grades N brazed/cermet H MG12 TA45 TI25 Carbide Grades HON 17

18 BOACHING - CHAMFEING INSET type N105/N " (6.0 mm) for use with Toolholder type SB105 SB110 SBU105 SBU110 Chamfering Part number Chamfer w w 1 l 5 l 2 l 3 usable from Ø Toolholder MG12 TA45 TI25 N SB105 / N SBU105 N SB N SBU110 on stock Δ 4 weeks P main recommendation M ο alternative recommendation K uncoatet grades S coatet grades N brazed/cermet H Carbide Grades HON

19 BOACHING - HEXAGON SOCKET INSET Type N105/N110 Hexagon socket from SW 2.5 for use with Toolholder Type SB105 SB110 SBU105 SBU110 Hexagon socket Part number SW r l 2 l 3 l 5 Pilot Ø X Toolholder MG12 TA45 TI25 N105.SW SW N105.SW SW N105.SW SW N105.SW SW 1.0 SB105 N105.SW SW N105.SW SW+0.1 N105.SW SW+0.1 N110.SW SW SB110 Δ N110.SW / SW+0.1/ SW SB110 Δ on stock Δ 4 weeks P main recommendation M ο alternative recommendation K uncoated grades S coated grades N brazed/cermet H Carbide grades HON 19

20 BOACHING - TOX INSET Type N105 Torx from T15 for use with Toolholder Type SB105 SBU105 Torx Part number Torx l 2 l 3 l 5 Pilot Ø Toolholder MG12 TA45 TI25 N105.TX T Δ N105.TX T Δ SB105 N105.TX T Δ N105.TX T Δ on stock Δ 4 weeks P main recommendation M ο alternative recommendation K uncoated grades S coated grades N brazed/cermet H Carbide grades HON

21 SUMMAY - BOACHING TOOLS Type SB105/SB110 - Holder can be located directly in the turret and m/c spindle Dimensions DIN Broaching Chamfering Width Tolerance grade D min t Inserts l 2 Toolholder Inserts Toolholder 2 C11 8 1,0 N C ,8 N SB SB N C ,8 N SB SB C ,0 N C ,0 N SB N SB C ,0 N SB N SB C N SB N SB C N SB N SB P9 6 1,1 N P9 8 1,5 N SB N SB P9 10 1,9 N SB N SB P9 10 1,9 N N P9 10 1,9 N SB N SB P9 12 2,4 N SB N SB P9 12 2,4 N N JS9 6 1,1 N JS9 8 1,5 N SB N SB JS9 10 1,9 N SB SB JS9 10 1,9 N N JS9 10 1,9 N N JS9 10 1,9 N SB N SB JS9 12 2,4 N SB N SB JS9 12 2,4 N N HON 21

22 BOACHING TOOLHOLDE Type SHU for use with Insert Type S117 SU117 Part number d h l l 1 l 2 D min f 1 Form SHU G SHU SHU F SHU A1 SHU SHU SHU A SHU SHU SHU B SHU SHU C SHU SHU SHU D SHU Further sizes upon request Spare parts Toolholder Screw TOX PLUS Wrench Dimensions in inch SHU T15P T15PQ SHU T20P T20PQ SHU T15P T15PQ HON

23 BOACHING TOOLHOLDE Type SH (14.0 mm) for use with Insert Type S117 SU117 Part number d h l l 1 l 2 D min f 1 Form SH G SH SH F SH SH A SH SH B SH SH C SH SH SH D SH SH SH E SH Further sizes upon request Spare parts Toolholder Screw TOX PLUS Wrench SH T15P T15PQ SH T20P T20PQ SH T15P T15PQ HON 23

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25 BOACHING TOOLHOLDE Type SH (14.0 mm) only usable for broaching devices EWS-Slot and BENZ LinA for use with Insert Type S117 SU117 Part number d l l 1 l 2 D min f 1 Form SH E F SH E SH E A SH E SH E B Further sizes for other device interfaces upon request Spare parts Toolholder Screw TOX PLUS Wrench SH T15P T15PQ SH E T15P T15PQ HON 25

26 BOACHING TOOLHOLDE Type H (17.0 mm) for broaching device Schwarzer for use with Insert Type S117 SU117 Part number d l l 1 l 2 D min f 1 a Form H H H H H H Further sizes for other device interfaces upon request A B C Spare parts Toolholder Screw TOX PLUS Wrench H /1439/1441/ T15P T15PQ H / T20P T20PQ HON

27 BOACHING THIS PAGE HAS BEEN ELECTONICALLY MODIFIED TOOLHOLDE Type SH117 with through coolant supply.551 (14.0 mm) for broaching device Schwarzer "2in1" for use with Insert Type S117 SU117 Part number d l l 1 l 2 D min f 1 a Form SH S SH S F SH S SH S A SH S B SH S SH S C Further sizes for other device interfaces upon request Spare parts Toolholder Screw TOX PLUS Wrench SH T15P T15PQ SH T15P T15PQ SH T20P T20PQ HON 27

28 THIS PAGE HAS BEEN ELECTONICALLY MODIFIED

29 BOACHING INSET Type Depth of groove up to S117 Tolerance grade C (14.0 mm).335 (8.5 mm) for use with Toolholder Type SH117 SHM117 SHU117 Keyways according to DIN138 Part number Nw w r E l t max f Form MG12 TA45 TN35 TI25 S F S S B Δ S S Δ S Δ D S Δ S Δ on stock Δ 4 weeks P main recommendation M ο alternative recommendation K uncoated grades S coated grades N brazed/cermet H Note: The insert form must correspond to the holder form. E.g.: Form A Toolholder = Form A Insert Carbide grades HON 29

30 BOACHING INSET Type Depth of groove up to S117 Tolerance grade P9.551 (14.0 mm).268 (6.8 mm) for use with Toolholder Type SH117 SHM117 SHU117 Keyways according to DIN138 Part number Nw w r E l t max f Form MG12 TA45 TN35 TI25 S G S S F S S A S B S C S D S E on stock Δ 4 weeks P main recommendation M ο alternative recommendation K uncoated grades S coated grades N brazed/cermet H Note: The insert form must correspond to the holder form. E.g.: Form A Toolholder = Form A Insert Carbide grades HON

31 BOACHING INSET Type Depth of groove up to S117 Tolerance grade JS9.551 (14.0 mm).335 (8.5 mm) for use with Toolholder Type SH117 SHM117 SHU117 Keyways according to DIN138 Part number Nw w r E l t max f Form MG12 TA45 TN35 TI25 S G S S F S S A S B S C S S D S E on stock Δ 4 weeks P main recommendation M ο alternative recommendation K uncoated grades S coated grades N brazed/cermet H Note: The insert form must correspond to the holder form. E.g.: Form A Toolholder = Form A Insert Carbide grades HON 31

32 BOACHING-CHAMFEING INSET Type S for use with Toolholder Type SH117 SHM117 SHU117 Chamfering Part number Nw w l f Form MG12 TA45 TN35 TI25 S F S A S B S C/D on stock Δ 4 weeks P main recommendation M ο alternative recommendation K uncoated grades S coated grades N brazed/cermet H Note: The insert form must correspond to the holder form. E.g.: Form A Toolholder = Form A Insert Carbide grades HON

33 SUMMAY - BOACHING TOOLS Type SH117 - Holder can be located directly in the turret and m/c spindle Broaching Chamfering Dimensions DIN Inserts w Toolholder Tool length Tool length l2 Inserts Toolholder l2 D min t Width Tolerance grade 6 C ,6 S ,12 SH S SH C ,3 S ,13 SH S SH C ,4 S ,13 SH S SH C ,2 S ,13 SH S SH C ,1 S ,15 SH S SH C ,6 S ,15 SH S SH C ,5 S ,15 SH S SH P9 17 2,7 S ,98 SH S SH P9 17 3,4 S ,98 SH S SH P9 22 4,1 S ,98 SH S SH P9 30 4,2 S ,98 SH S SH P9 38 5,7 S ,97 SH S SH P9 40 6,8 S ,97 SH S SH JS9 17 2,7 S ,01 SH S SH JS9 17 3,4 S ,01 SH S SH JS9 22 4,1 S ,01 SH S SH JS9 30 4,2 S ,01 SH S SH JS9 38 5,7 S ,01 SH S SH JS9 38 8,5 S ,00 SH S SH JS9 40 6,8 S ,01 SH S SH HON 33

34 Application Tips: - It is important to use a machine with mechanical spindle lock. - The use of proper coolant is key to a good surface finish, long tool life as well as chip evacuation. - A relief groove or the possibility for a "ramp down" exit out of the cut is necessary at the end of the broached groove. - Setting of the tool if very important. Double check the component diameter before taking the first pass. - The tool should be set at the 12 o'clock position to ensure that chips fall away from the groove. - Take an accurate measurement of the insert and program the dimension into the machine tool parameter. - Position the tool at the start position of the first stroke and program a stop to perform a visual check to assure a collision free first pass of the tool. Machining example: Bore diameter 32 mm, groove width 8 mm: At a radius of 16 mm and with a clearance of 0,2 mm for safety at the r 0,2 mm corner radii, the tool has to be set at 15,292 mm in X-axis to avoid any collision at the beginning of the process. Calculation of the start position b 1 : c 2 = a 2 + b 2 b 2 = c 2 - a 2 b = c 2 - a 2 b = b = 15, b 1 = b - Clearance distance b 1 = 15,492-0,2 = 15,292 mm equals as a start position at Ø mm HON

35 400 N/mm 2 Insert type S/SU117 Feed rate mm/min Insert type N/NU N/mm 2 Insert type N/NU110 In-feed per stroke in mm lb/in 2 Insert type S/SU117 Feed rate inch/min lb/in 2 Insert type N/NU105 Insert type N/NU In-feed per stroke in inch HON 35

36 POGAMMING EXAMPLE Example for broaching on a TAUB TNA 400 with C-Axis NC - Program N (BOACHING) G97 T M5 M17 G94 L1 = M8 M19 N100 G0 XL1 Z5 G1 Z-25 F8000 G0 X G0 Z5 L1 = L N200 G22 P100 Q200 H45 Sequence Number and Application constant PM, Tool callout, Spindle Stop C - axis ON Feed ate in mm/min choose Parameter for start Ø Coolant ON, Spindle Break ON Sequence Number for repetition STAT Start position in X and Z in front of part Linear move in Z at feed rate of 8000 mm/min apid move in X to start Ø i.e. drop down position apid move in Z to start position. As Ø programming is in effect the depth of cut must be doubled (Depth of Cut is 0.08 mm) Sequence Number of repetition END. epetition Cycle with Sequence Number from STAT to END and Number of repetitions Example: - Groove according to table in bore Ø 32 mm - Groove width 8 C11 - Depth of Cut per Stroke 0.08 mm - The Number of Strokes resulted out of complete cutting depth from start position to the bottom of the groove divided by depth of cut per stroke - This Value must then be multiplied by 2 ( because Ø Programming) and Value is programmed as the Number of Strokes in the NC-Programme. Calculation: - Starting Position = Security Distance + Distance from Ø 32 mm to Cutting Edge (see Example on Page 34) equals a segment height of mm + Security Distance of 0.20 mm to a total of mm. - Starting Position = mm (32 - [0.708 x 2] = mm. - The groove depth of 2.90 mm added to the mm = mm. - This is the dimension from the starting position to the bottom of the groove and in order to program this on the Ø, the mm dimension must be multiplied by 2 which will equal the sum of mm. - When the mm is divided by (2 x 0.08 mm) = 0.16 mm depth per stroke the esult will be 45.1 Strokes and therefore 45 total Strokes are programmed. The remainder of 0.1 Strokes to achieve the finish dimension must be programmed using the fine correction. Attention: The true depth of cut for the insert will be 0.08 mm HON

37 POGAMMING EXAMPLE Example for broaching on SIEMENS Control Machines with lockable Spindle NC - Program N (BOACHING) T M5 LF M LF G94 LF 1 = LF M8 LF N100 LF G0 X1 Z5 LF G1 Z-25 F8000 LF G0 X G0 Z5 1 = N200..LF Sequence Number and Application Tool callout, Spindle Stop Brake ON Feed ate in mm/min choose Parameter for start Ø Coolant ON Sequence Number for repetition STAT Start position in X and Z in front of part Linear move in Z at feed rate of 8000 mm/min apid move in X to start Ø i.e. drop down position apid move in Z to start position. As Ø programming is in effect the depth of cut must be doubled (Depth of Cut is 0.08 mm) Sequence Number of repetition END. epetition Cycle with Sequence Number from STAT to END and Number of repetitions. Example: - Groove according to table in bore Ø 32 mm - Groove width 8 C11 - Depth of Cut per Stroke 0.08 mm - The Number of Strokes resulted out of complete cutting depth from start position to the bottom of the groove divided by depth of cut per stroke - This Value must then be multiplied by 2 ( because Ø Programming) and Value is programmed as the Number of Strokes in the NC-Programme. Calculation: - Starting Position = Security Distance + Distance from Ø 32 mm to Cutting Edge (see Example on Page 34) equals a segment height of mm + Security Distance of 0.20 mm to a total of mm. - Starting Position = mm (32 - [0.708 x 2] = mm. - The groove depth of 2.90 mm added to the mm = mm. - This is the dimension from the starting position to the bottom of the groove and in order to program this on the Ø, the mm dimension must be multiplied by 2 which will equal the sum of mm. - When the mm is divided by (2 x 0.08 mm) = 0.16 mm depth per stroke the esult will be 45.1 Strokes and therefore 45 total Strokes are programmed. The remainder of 0.1 Strokes to achieve the finish dimension must be programmed using the fine correction HON 37

38 CHOICE OF CABIDE GADES I Carbide Grades uncoated coated Wear resistance Cutting speed Toughness Feed rate TH35 TH35 TH35 TA45 TA45 TA45 TI25 TI25 TI25 TN35 TN35 TN35 MG12 MG12 MG P M K Steel Stainless steel Grey cast iron / Aluminum HON

39 CHOICE OF CABIDE GADES II Carbide Grades uncoated coated Synthetic cutting-tool material Hardened materials H 01 Toughness High temp. alloys S Non ferrous metals MG12 TI25 TA45 Feed rate Wear resistance Cutting speed 10 N HON 39

40 CABIDE GADES UNCOATED GADES MG12 - a universal grade with good wear resistance. Used at low or medium cutting speeds for machining steel, cast iron and non ferrous materials COATED GADES TN35 - a very popular grade TiN coated used to low or medium cutting speeds. Also recommanded for machining stainless steel or exotic alloyed materials TI25 - a TiCN coated grade with high abrasion resistance. ecommended for machining steel and non ferrous materials at medium cutting speeds TA45 - a TiAlN coated grade. This coating has a very high temperature stability and high hardness. TH35 - new standard grade - extreme Oxidation resistance with high hardness and very good coefficient of friction HON