MaxiMill HFC 'Feed matters', rapid milling

Transcription

1 MaxiMill HFC 'Feed matters', rapid milling

2 CERATIZIT - secrets of success Secrets of success CERATIZIT is your partner for exceptional hard material solutions. Hard materials and tools from CERATIZIT - our solutions to complex problems are an integral part of our customers' success. Our products guarantee: economy - long life - speed! And it is precisely this combination which gives our business partners a direct competitive advantage. Premier performance is only possible through a total appreciation of the requirements of our business partners. A performance achieved through flexible thinking and continuous dialogue with our customers. A pioneering spirit and a deep understanding of powder metallurgy characterize the history of CERATIZIT. One of the attributes of our company philosophy is the search for perfection: target oriented - sustainably - passionately! Intensive research and development activities, taking into account the precise requirements and working processes of the customer, are today's investment for the solutions of tomorrow - and beyond. Corporate values The views and focus of our business partners matter Innovative and flexible thinking matters Communication matters Employee development matters Professionalism matters Our environment matters Tailored cutting tool solutions Cutting materials, coatings, inserts, tooling systems and machining solutions - all this is included in the cutting tool division at CERATIZIT. Worldwide well-known companies process advanced materials applying cutting tool products from CERATIZIT: from the automotive industry to the aerospace industry, mechanical engineering, and tool construction to the oil industry. The basis of these long-term business relations is the faith of the customers in the extensive know-how of the carbide specialists. 2

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4 MaxiMill HFC system Extreme face milling The CERATIZIT solution: MaxiMill HFC With feed rates up to 3 mm/tooth and closely pitched tools, very high chip removal rates are achieved. Extreme feed rates Soft cutting with chip groove M50 HyperCoat inserts 1 Face milling with maximum feed rate (3 mm per tooth) 2 Ramping for the production of deep pockets 3 Plunge milling for maximum chip removal rates (3 mm per tooth) normal close Milling cutters Ø mm 4

5 MaxiMill HFC Customer benefits Maximum tool life HyperCoat coating Application advantages CTP 1235 CTP 2235 CTC 3215 SR Process security Optimised cutter bodies using Finite Element Modelling The tool is stable and optimised using Finite Element Modelling: Maximum tool life with reduced tendency to vibration - Reduced machining noise and vibration, light cutting geometries - Maximum tool life thanks to HyperCoat coating - Cutter body optimised using FEM Quick cutting advantage for tooling engineers: High cutting performance and good security when milling with extreme feed rates Reduced machining noise and vibration Light cutting geometries Extremely positive cutting angle: Soft cutting and reduced cutting noise! The cutting forces are mainly in the axial direction: Even with long overhang lengths there is almost no vibration, and little stress on the machine spindle. Flexibility Coolant holes designed for economic lubrication Tapered coolant exit hole for minimum quantity lubrication. Suitable for minimum quantity lubrication. Increased flexibility when choosing the coolant (air, mist or lubricant). Optimum position of coolant exit hole close to the cutting edge. Reduced tool and work piece heating. Support for chip evacuation when milling deep pockets. Central coolant supply in all tools. 5

6 Grade overview Wear resistance / toughness Wear resistance SR226+ CTP Toughness Wear resistance CTP Toughness Wear resistance CTC Toughness 6

7 Grade overview Grade designation CTP1235 CTP2235 SR226+ Standard designation Cutting material Application range CTC3215 HC-K15 C HC-P35 P HC-P40 P A R F N S H HC-M30 P HC-M40 P HC-P25 C HC-M25 C HC-K20 C Steel Stainless Cast iron Non ferrous metals Heat resistant Hard materials Main application Extended application 7

8 Inserts Shape X -M50 CTC3215 SR226+ CTP1235 CTP2235 (l) Type, d l s l 1 r α description [ ] 09 XDLT 09T308SR-M50 R R R R XOLT SR-M50 R R R R Steel RRr Stainless d rrr Cast iron R Non ferrous metals l Heat resistant rrr l 1 s Hard materials Main application Extended application International CERATIZIT range, for present availability see price list r Ordering example: 10 pieces XDLT 09T308SR-M50 CTP1235 CHFC-09/12 AHFC-09/12 GHFC-09/12 8

9 Face milling cutters CHFC-09/ ,5 (-2 ) l 2 Ø DIN 1835A Ø d A a l 1 Type, l 1 l 2 d A a n max description min -1 z 25 CHFC.25.R A XD_T 09T3 25 CHFC.25.R A XD_T 09T3 32 CHFC.32.R A XD_T 09T3 32 CHFC.32.R A XO_T CHFC.35.R A XO_T 1204 Ordering example: 1 piece CHFC.25.R A Supply details: cutter body and clamping screws for inserts XD_T 09T /M3,5X7,2/T /TORX T15 DMSD 3,2Nm/SORT T15 XD_T 09T /M3,5X8,6/T /TORX T15 DMSD 3,2Nm/SORT T15 XO_T /M4,5X10,5/T /TORX T20 DMSD 5,0Nm/SORT T20 XD_T 09T3 XO_T

10 Face milling cutters GHFC-09/ ,5 (-2 ) SW Ø Ø d G Ø d A a l 2 Type, l 2 d A d g a n max description min -1 z 25 GHFC.25.R XD_T 09T3 25 GHFC.25.R XD_T 09T3 32 GHFC.32.R XD_T 09T3 32 GHFC.32.R XO_T GHFC.35.R XO_T 1204 Ordering example: 1 piece GHFC.25.R Supply details: cutter body and clamping screws for inserts n max = depends on the overhang and number of interfaces in the complete tool XD_T 09T /M3,5X7,2/T /TORX T15 DMSD 3,2Nm/SORT T15 XD_T 09T /M3,5X8,6/T /TORX T15 DMSD 3,2Nm/SORT T15 XO_T /M4,5X10,5/T /TORX T20 DMSD 5,0Nm/SORT T20 XD_T 09T3 XO

11 Face milling cutters AHFC-09/ ,5 (-2 ) d d A a h Ø Type, da a d h n max description min -1 z 32 AHFC.32.R XD_T 09T3 35 AHFC.35.R XD_T 09T3 40 AHFC.40.R XD_T 09T3 42 AHFC.42.R XD_T 09T3 50 AHFC.50.R XD_T 09T3 52 AHFC.52.R XD_T 09T3 63 AHFC.63.R XD_T 09T3 66 AHFC.66.R XD_T 09T3 40 AHFC.40.R XO_T AHFC.42.R XO_T AHFC.50.R XO_T AHFC.52.R XO_T AHFC.63.R XO_T AHFC.66.R XO_T AHFC.80.R XO_T AHFC.100.R XO_T 1204 Ordering example: 1 piece AHFC.32.R Supply details: cutter body and clamping screws for inserts XD_T 09T /M3,5X8,6/T /TORX T15 DMSD 3,2Nm/SORT T /M8,0x30,0 XD_T 09T /M3,5X8,6/T /TORX T15 DMSD 3,2Nm/SORT T15 XO_T /M4,5X10,5/T /TORX T20 DMSD 5,0Nm/SORT T /M8,0x30,0 XO_T /M4,5X10,5/T /TORX T20 DMSD 5,0Nm/SORT T20 S4/SW4 S4/SW4 XD_T 09T3 XO_T

12 Cutting data Tool, material v c (m/min) f z (mm) a p (mm) v c (m/min) f z (mm) a p (mm) v c (m/min) f z (mm) a p (mm) MaxiMill HFC ,1-2,5 0,1-0,5 0,1-1,5 0,5-1, ,1-2,5 0,1-0,5 0,1-1,5 0,5-1, ,1-2,5 0,1-0,5 0,1-1,5 0,5-1,0 MaxiMill HFC ,1-3,0 0,5-1,2 0,1-2,0 1,0-2, ,1-3,0 0,5-1,2 0,1-2,0 1,0-2, ,1-3,0 0,5-1,2 0,1-2,0 1,0-2,0 Recommendations for economic milling HFC a p 2,5 2 l a p 0,1-1 0,5-2 f z 2,5-0,10 3,0-0,25 1,5 1 0,5 0 0,5 1 1,5 2 2,5 3 f z 12

13 MaxiMill HFC Feed matters, rapid milling Reduced machining noise and vibration, light cutting geometries Maximum tool life with HyperCoat coating Process security thanks to optimised cutter bodies using Finite Element Modelling

14 Cutting data Grades / materials A R F N S H Work piece material Type of treatment / alloy annealed 0,15% C Non alloyed steel annealed 0,15% - 0,45% C tempered 0,45% C Low alloyed steel annealed tempered tempered High alloyed steel annealed tempered Stainless steel annealed ferritic tempered martensitic annealed ferritic / martensitic Stainless steel quenched austenitic quenched duplex hardened martensitic / austenitic pearlitic / ferritic Grey cast iron pearlitic / martensitic Spheroidal cast iron ferritic pearlitic ferritic Malleable cast iron pearlitic Aluminium wrought alloys non hardened hardened non hardened < 12% Si Aluminium cast alloys hardened < 12% Si non hardened > 12% Si machining alloy stock (1% Pb) Copper and brass, red bronze copper alloys (bronze, brass) bronze lead-free copper and electrolytic copper thermosetting plastics Non-metallic materials fibre reinforced plastics hard rubber annealed Fe base hardened Fe base Heat resistant alloys annealed Ni or Co base hardened Ni or Co base HRC cast Ni or Co base Nmm 2 Titanium alloys Ni or Co base alpha + beta alloys Tempered steel hardened and tempered hardened and tempered Chilled castings cast Tempered cast iron hardened and tempered * Rm = ultimate tensile strength, measured in MPa VDI 3323 group Hardness HB / R m 440* 37 R m 1050* HRC HRC HRC 14

15 Cutting data Grades / materials Coated carbide CTC3215 CTP1235 CTP2235 SR226+ v c [m/min] v c [m/min] v c [m/min] v c [m/min] v c [m/min] v c [m/min] v c [m/min] v c [m/min] Recommended application Possible application 15

16 Application data HFC-09 Helical plunge milling D M D max = maximum diameter for flat bottom ground D min = minimum hole diameter D M = D max - or D min - D max D min α R max [ ] , , , , , , , , ,6 D α R max 360 [ ] , , , , , , , , ,6 a p = D M x π x tan α R Axial plunging X max ,75 Angled ramping α R max [ ] 25 3,6 32 2,0 35 1,6 40 1,2 42 1,1 50 0,9 52 0,8 63 0,8 66 0,7 16

17 Application data HFC-09 Depth of cut and remaining material r R=2mm l B r a p max 9 5,9 0,8 1 l=9mm R = programmed radius B ap max Profile when shoulder and slot milling Width of cut for flat surfaces X B (2 x B) 5,9 X B Ø Engagement data when plunge milling Z max Z max f z Y max initial min max Y 7,5 0,10 0,08 0,15 < 0,7 x Tool offset with optimum overlap Tool offset for unstable conditions Z Y Z/2 Y 17

18 Application data HFC-12 Helical plunge milling D M D max = maximum diameter for flat bottom ground D min = minimum hole diameter D M = D max - or D min - D max D min α R max [ ] , , , , , , , , , ,6 D α R max 360 [ ] , , , , , , , , , ,6 a p = D M x π x tan α R Axial plunging X max ,15 Angled ramping α R max [ ] 32 7,2 35 4,4 40 2,9 42 2,7 50 1,5 52 1,5 63 1,1 66 1,1 80 1, ,7 18

19 Application data HFC-12 Depth of cut and remaining material r R=3mm l B r a p max 12 8,3 1,0 2 l=12mm R = programmed radius B ap max Profile when shoulder and slot milling Width of cut for flat surfaces X B (2 x B) 8,3 X B Ø Engagement data when plunge milling Z max Z max f z Y max initial min max Y 10 0,15 0,10 0,20 < 0,7 x Tool offset with optimum overlap Tool offset for unstable conditions Z Y Z/2 Y 19

20 Find your personal distribution partner at: CERATIZIT worldwide production sites and support centres CERATIZIT worldwide sales centres CERATIZIT worldwide distribution partner network 448 CERATIZIT - worldwide Headquarters: CERATIZIT S.A. Parent company in Luxembourg CERATIZIT Luxemburg Sarl Route de Holzem, B.P. 51 L-8201 Mamer Tel.: Fax: info@ceratizit.com Contact for further information: CERATIZIT Austria Gesellschaft m.b.h. A-6600 Reutte/Tyrol Tel.: +43 (5672) Fax: +43 (5672) info.austria@ceratizit.com EN We reserve the right to make technical changes for improvement of the product.