MAXIMILL MILLING SYSTEM ENGINEERED SIMPLICITY. 8 Cutting Edges. More milling. More parts. More profits.

Transcription

1 MAXIMILL 491 MILLING SYSTEM ENGINEERED SIMPLICITY 8 Cutting Edges. More milling. More parts. More profits.

2 22 We work hard to make things easy. It takes a lot of engineering and know-how to make a complicated process simple. But that s what we do. We think ahead, keeping your needs out in front. We re known for innovative solutions, so as the metalworking industry evolves, CERATIZIT will have what you need. And you ll know where to find us out in front. NOTE: Keep this catalog handy for future reference and ordering. MAXIMILL 491: MILLING SYSTEM. 8 CUTTING EDGES. NOTE: KEEP THIS CATALOG for future reference and ordering. 1 SIMPLE DESIGN.

3 MaxiMill 491 ENGINEERED SIMPLICITY 3 CERATIZIT A World of Innovation Your reliable single source for unique solutions in cutting tools, solid rod, wear component, and wood and stone applications World renowned for exceptional products optimized for hard-to-machine materials and your equipment parameters Working to invent new solutions for the challenges of tomorrow Contents Introduction System overview 4 Advantages and benefits 7 MaxiMill 491 System Productivity is our product. Grade overview and descriptions 10 Our business is increasing productivity for your business. We take that very seriously. That s why CERATIZIT products are made so we can guarantee cost efficiency and reliable performance every day. 0,20 20 Geometry overview15 MaxiMill 491 System 16 Technical information Contents Cutting data 22 Replacement parts 26

4 42 MaxiMill 491 System overview MaxiMill 491 The new shoulder milling system The new MaxiMill 491 shoulder milling system from Cutting Solutions by CERATIZIT features 8 usable cutting edges per insert and provides excellent performance, quality and priceperformance ratio. Thanks to the latest grinding technology, these precision inserts can be produced with tolerance H. This enhances the service life of the cutting edge, allowing top-quality surfaces to be achieved on your component. MaxiMill 491 System overview TOOL DETAILS Quick and easy insert mounting Reduced vibration is a particular advantage when it comes to low-power machines and thin-walled, unstable components. Long-lasting tool body in new material and Hard & Tough coating Tools available with close or wide pitch TorxPlus clamping screw profile Exact profile Patented system Chamfered coolant holes suitable for MQL, emulsion and compressed air

5 MaxiMill 491 System overview 5 Extended range of sizes and applications The MaxiMill 491 system offers an extended range of cutter bodies, from 1.5" to 6" in diameter, as well as 32mm to 160mm diameter for metric users. The system uses a 12 mm SNHU insert with 0.031" corner. Available in shell, shank and threaded-shank styles with close and wide pitches for each diameter. High-performance chip grooves and geometries -F10, -F50, -M50, -R50 make these inserts anything but standard. Engineered with the latest grade technologies, they re ideal for applications in steel, cast iron, stainless steel and aluminum in ISO ranges P, K, M and N. INSERT DETAILS System overview Latest CVD and PVD grade technology Precision-ground insert with tolerance H Up-to-date chip groove geometries: -F10, -F50, -M50 and -R50 MaxiMill 491 Numbered cutting edges with additional CERATIZIT chip groove code 8 usable cutting edges per insert with a p max.312" / 8 mm

6 62 MaxiMill 491 System overview shoulder milling system with 8 cutting edges per insert Exact profile Easy handling Ground precision insert with tolerance H MaxiMill 491 System overview Applications CERATIZIT puts most of the work where it belongs in engineering so you get the most out of it, in these operations: Shoulder milling Face milling Peripheral milling Slot milling Trochoidal slot milling Shoulder milling Face milling Peripheral milling Slot milling Trochoidal slot milling Material groups P M K N S H Detailed information Pitch Ø range Inserts inch: Ø 1.50" to 6.00" metric: Ø 32 to 160 mm SNHU 12..

7 MaxiMill 491 Advantages and benefits 7 System advantages and benefits Complete finishing and roughing operations with the same insert in aluminum, steel, cast iron and stainless steel. With eight cutting edges per insert and an approach angle of exactly, you get perfect finishes no further machining needed. Inserts are available in the latest grade technologies BLACKSTAR and SILVERSTAR. Easy use Self-positioning insert Quick and easy cutter mounting Ground precision insert with tolerance H Perfect axial run-out precision and concentricity Long tool life Reduced vibration with low-power machines Reliability Outstanding surface quality Double positive clearance angle Very soft cutting action 20-30% lower power consumption on the spindle Reduced tendency for vibration also with low-power machines Extended application range Large open chip pockets with wide pitch Optimal chip evacuation during the milling process Maximum repeatability, thanks to innovative insert design with generous contact faces Perfectly adapted chip pockets Advantages and benefits MaxiMill 491 Over 2x the tool life! Success example with ISO P forged stainless steel Cutting data Competitor CERATIZIT Chip groove PM M50 Milling cutter 4-063Q22-14H A R Insert 4R M-PM SNHU SR-M50 Grade GC4240 CTPP235 Vc [ft/min] Vc [m/min] fz [in/tooth] 0.006" 0.006" fz [mm/tooth] ap [inch].040".120".040".120" ap [mm] Parts produced [qty] 168 The customer was enthusiastic about the surface, optimal chip formation and low power consumption. Considerable cost saving thanks to reduced tool changing time and long tool life. QUANTITY OF PARTS PRODUCED CERATIZIT MaxiMill 941 Competitor PARTS 168 PARTS Work piece description : bearing case, linear guidance Work piece material: / 16MnCr5 (forged) Coolant: emulsion

8 The CERATIZIT Designation System 82 for cutting materials C TP P The CERATIZIT Designation System 1 Manufacturer: CERATIZIT 2 Cutting material W Uncoated carbide C CVD coated carbide P PVD coated carbide T Uncoated cermet E Coated cermet N Uncoated silicon nitride M Coated silicon nitride S Mixed ceramic I Sialon D PCD B CBN L CBN coated H Sintered HSS 3 Main application (material) Variant 1: number 1 Steel 2 Stainless steel 3 Cast iron 4 Light and non-ferrous metals, non-metals 5 Heat-resistant alloys, titanium 6 Hard materials 7 Universal grade for a variety of application 4 Main applications (machining method) 1 Turning 2 Milling 3 Parting and grooving 4 Drilling 5 Threading 6 Others 7 Universal grade for a variety of applications 5 ISO 513 Application range For example: ISO P35... Main application (material) Variant 2: ISO letter P Steel M Stainless steel K Cast iron N Light and non-ferrous metals, non-metals S Hea-resistant alloys, titanium H Hard materials X Universal grade for a variety of applications

9 MaxiMill491 9MaxiMill 491

10 Grade overview 10 2 Grade Overview

11 Grade overview 11 Extreme tools for extreme materials. We tailor the properties of CERATIZIT cutting tools with a special powder metallurgical process. The result: carbide grades with outstanding wear and heat resistance under extreme conditions common with difficult-to-machine materials. The characteristics for each grade will help you decide which is best for your applications. The first choice for high cutting performance in interrupted cutting actions or with difficult-to-machine materials. Highly wear-resistant, thanks to TiN/TICN/AI2O3 coatings. Exceptional adhesion makes these grades ideal for machining steel and cast iron. Grade designation ISO ANSI CTCP230 HC-P30 C6 C BLACKSTAR TM Standard designation *Type of cutting material Application range P M K N S H HC-K25 C2 C Steel Stainless Cast iron Non-ferrous metals Heat-resistant Hard materials Grade overview HC-M25 - C CTPP235 HC-P35 C5 P SILVERSTAR TM HC-M30 - P CTPM240 HC-M40 - P SILVERSTAR TM HC-P40 C5 P CTCK215 BLACKSTAR TM HC-K15 C3 C CTPK220 SILVERSTAR TM HC-K20 C2 P CTWN215 HW-N15 C3 W HW-K15 C3 W Main application Extended application

12 Grade descriptions 12 2 CTCP230 BLACKSTAR TM HC-P30 HC-K25 HC-M25 Specification: Composition: Co 10.5%; mixed carbides 2.0%; WC balance Grain size: 1-2 µm Hardness: HV Coating specification: CVD TiCN-AI 2 O 3 Recommended application: First choice for dry machining of steels at high cutting speeds. CTPP235 SILVERSTAR TM HC-P35 HC-M30 Specification: Composition: Co 10.5%; mixed carbides 2.0%; WC balance Grain size: 1-2 µm Hardness: HV Coating specification: PVD TiAlTaN Recommended application: Particularly suitable for the wet machining of steels. Grade descriptions CTPM240 SILVERSTAR TM HC-M40 HC-P40 Specification: Composition: Co 12.5%; mixed carbides 2.0%; WC balance Grain size: 1 µm Hardness: HV Coating specification: PVD TiAlTaN Recommended application: The first choice for the machining of austenitic steels. CTCK215 BLACKSTAR TM HC-K15 Specification: Composition: Co 6.0%; mixed carbides 2.0%; WC balance Grain size: 1 µm Hardness: HV Coating specification: CVD TiN; MT-TiCN; AI 2 O 3 Recommended application: The first choice for the machining of cast iron at high cutting speeds.

13 Grade descriptions 13 CTPK220 SILVERSTAR TM HC-K20 Specification: Composition: Co 6.0%; mixed carbides 2.0%; WC balance Grain size: 1 µm Hardness: HV Coating specification: PVD TiAlTaN Recommended application: Optimal for the machining of high-tensile cast iron materials when toughness is required. CTWN215 HW-N15 HW-K15 Specification: Composition: Co 6.0%; others 0.2%; WC balance Grain size: submicron Hardness: HV Recommended application: The uncoated carbide grade for the machining of aluminum and other non-ferrous metals. Over 75% more parts produced! Grade descriptions Success example with low alloy carbon steel ST44-2 (1.0256) Cutting data Competitor CERATIZIT Chip groove F57 M50 Milling cutter F4048.B Z06 A R Insert SNMX SNHU SR-M50 Grade WKP35S CTPP235 Vc [ft/min] Vc [m/min] fz [in/tooth] fz [mm/z] ap [inch] ap [mm] Parts produced [qty] 140 The customer was satisfied with the test result and would like to switch to MaxiMill 491 as soon as possible. QUANTITY OF PARTS PRODUCED CERATIZIT MaxiMill 941 Competitor PARTS 140 PARTS Work piece description: heat exchanger Work piece material: low alloy carbon steel Coolant: emulsion

14 2 14 MaxiMill 491 system Geometry overview MaxiMill 491 system Geometry overview

15 MaxiMill 491 system Geometry overview 15 -F10 Machining conditions Highly positive geometry Sharp cutting edge Low tendency to adhesion First choice for non-ferrous metals 38 CTWN215 f z [in] 0.002" " f z [mm] 0,05 0,25 CTWN215 CTWN215 CTWN215 -F50 Positive geometry Finishing and roughing First choice for stainless steel materials 31 0,15 CTPM240 Machining conditions CTPM240 Geometry overview f z [in] 0.004" " -M50 Universal geometry Light to medium roughing operations First choice for general steel materials 25 f z [mm] 0,10 0,20 0,15 Machining conditions CTCP230 CTPP235 CTPM240 CTPP235 CTCP230 CTPM240 MaxiMill 491 system f z [in] 0.004" " f z [mm] 0,10 0,25 -R50 Stable geometry Roughing For heavily interrupted cut First choice for cast iron materials 20 0,20 Machining conditions CTCK215 CTPK220 CTPK220 CTCK215 f z [in] 0.004" " f z [mm] 0,10 0,30

16 MaxiMill 491 system 16 2 SNHU.. P M K N S H CTCP230 CTPP235 CTPM240 CTCK215 CTPK220 CTWN215 INCH METRIC d l s r d 1 d l s r d 1 [in] [in] [in] [in] [in] [mm] [mm] [mm] [mm] [mm] SNHU FR-F M50 -F50 -F10 SNHU SR-F SNHU SR-M SNHU SR-R MaxiMill 491 system SNHU.. -R50 d r d 1 l s V C B8-B10 B14 B24-B27 CTCP230 CTPP235 CTPM240 CTCK215 CTPK220 CTWN215 d l s r d 1 d l s r d 1 57% more parts produced! Success example with ISO K Cutting data Competitor CERATIZIT Chip groove D18 R50 Milling cutter R SA A491..R Insert OFEN TN-D18 SNHU SR-M50 Grade MK1500 CTPP235 Vc [ft/min] Vc [m/min] fz [in/tooth] fz [mm/z] 0,16 0,16 ap [inch] ap [mm] Parts produced [qty] The customer was very enthusiastic about the excellent surface and the system in general. QUANTITY OF PARTS PRODUCED CERATIZIT MaxiMill 941 Competitor 255 PARTS 400 PARTS Work piece description: base plate of hydraulic pump Work piece material: / GG25 Coolant: emulsion

17 MaxiMill 491 system A Ø d Ø d A H6 A a h INCH Ø d 1 d 1 [in] Type, description h [] d [in] d A [in] a [in] z n max [min -1 ] [Nm] 1.50 A R A EF SNHU E A R A EF SNHU E A R A EF SNHU E A R A EF SNHU E A R A EF SNHU E A R A EF SNHU E A R A EF SNHU E A R A EF SNHU E A R A EF SNHU E A R B EF SNHU E A R B EF SNHU E A R B EF SNHU E A R B EF SNHU E02 METRIC A MaxiMill 491 system d 1 [mm] Type, description h [mm] d [mm] d A [mm] a [mm] z n max [min -1 ] [Nm] 40 A R SNHU E01 40 A R SNHU E02 50 A R SNHU E02 50 A R SNHU E02 63 A R SNHU E02 63 A R SNHU E02 A491..R SNHU E02 A491..R SNHU E A R SNHU E A R SNHU E A R SNHU E A R SNHU E A R SNHU E A R SNHU E02 E E

18 MaxiMill 491 system 18 2 C l 1 C Ø d 1 Ø d A h6 a l 2 -A d 1 [in] Type, description l 1 [in] l 2 [in] d A [in] a [in] z n max [min -1 ] [Nm] 1.25 C R B-150-EF SNHU E C R A-250-EF SNHU E01 MaxiMill 491 system C d 1 [mm] Type, description l 1 [mm] l 2 [mm] d A [mm] a [mm] z n max [min -1 ] [Nm] 32 C R A SNHU E01 32 C R B SNHU E01 E

19 MaxiMill 491 system Starting parameters for example materials 19 Materials Insert [ft/min] [m/min] Coolant CrMnMoS N/mm 2 SNHU SR-M50 CTPP dry X6CrNiMoTi N/mm 2 SNHU SR-F50 CTPM dry 5.1 EN-GJL-250 HB 1 SNHU SR-R50 CTCK dry Alu 450 N/mm 2 SNHU SR-F10 CTCK Minimum quantity lubrication If a e < 50% use correction list a p [ i n ] Starting parameters for example materials f z [ i n ] MaxiMill 491 system a p [ m m ] ,05 0,10 0,15 0,20 0,25 f z [ m m ]

20 2 20 MaxiMill 491 system Correction of feed rate f z These parameters apply for cutting width (a e ) below 50% Example: Starting value [f z ] = 0.003" / mm a e = 30% Corrected value [f z ] = 0.006" / 0.15 mm ae Starting values f z [in] from starting parameter diagram MaxiMill 491 system Correction of feed rate f z a e [ % ] Corrected values f z [in] Starting values f z [mm] from starting parameter diagram a e [ % ] 100 0,050 0,075 0,100 0,125 0,150 0,200 0,250 0,300 0,350 0, ,05 0,10 0,15 0,20 0,25 0,30 0,35 0,40 0,45 Corrected values f z [mm]

21 Cutting data 21 Cutting data

22 Cutting data 22 2 Grades, material Work piece material Type of treatment / alloy VDI 3323 group Hardness HB annealed 0.15 % C Non-alloyed steel annealed 0.15% 0.45% C tempered 0.45% C annealed 6 1 P Low-alloyed steel High-alloyed steel tempered tempered annealed tempered 7 / Cutting data Grades, material inch M K Stainless steel Stainless steel Grey cast iron Spheroidal cast iron Malleable cast iron Aluminum wrought alloys annealed tempered heat-treated quenched quenched hardened non-hardened hardened ferritic /martensitic martensitic ferritic /martensitic austenitic ferritic/austenitic (duplex) austenitc, precipitation hardened (PH) pearlitic /ferritic pearlitic / martensitic ferritic pearlitic ferritic pearlitic Aluminum cast alloys non-hardened hardened non-hardened < 12% Si < 12% Si 24 > 12% Si 25 N Copper and copper alloys (bronze, brass) machining alloy stock (1% Pb) brass, red bronze bronze 26 () lead-free copper and electrolytic copper thermosetting plastics 29 Non-metallic materials fiber-reinforced plastics 29 hard rubber 30 annealed Fe-based S Heat-resistant alloys hardened annealed hardened cast Fe-based Ni- or Co-based Ni- or Co-based HRC Ni- or Co-based N/mm² (350) 35 (320) Titanium alloys pure titanium alpha and beta alloys 36 R m 440* 37 R m 1050* H Tempered steel Chilled castings hardened and tempered hardened and tempered cast HRC HRC Tempered cast iron hardened and tempered HRC * R m = ultimate tensile strength, measured in MPa

23 Cutting data Grades, material 23 INCH CTCP230 CTPP235 CTPM240 CTCK215 CTPK220 CTWN215 [ft/min] [ft/min] [ft/min] [ft/min] [ft/min] [ft/min] [ft/min] [ft/min] [ft/min] [ft/min] [ft/min] [ft/min] Grades, material inch The cutting data are non-binding indications for the operator. It is recommended to adapt them to the current conditions. Cutting data

24 Cutting data 24 2 Grades, material Work piece material Type of treatment / alloy VDI 3323 group Hardness HB annealed 015 % C Non-alloyed steel annealed 0.15% 0.45% C tempered 0.45% C annealed 6 1 Cutting data Grades, material metric P M K Low-alloyed steel High-alloyed steel Stainless steel Stainless steel Grey cast iron Spheroidal cast iron Malleable cast iron Aluminum wrought alloys tempered tempered annealed tempered annealed tempered heat-treated quenched quenched hardened non-hardened hardened ferritic /martensitic martensitic ferritic / martensitic austenitic ferritic /austenitic (duplex) austenitc, precipitation hardened (PH) pearlitic /ferritic pearlitic/martensitic ferritic pearlitic ferritic pearlitic 7 / Aluminum cast alloys non-hardened hardened non-hardened < 12% Si < 12% Si 24 > 12% Si 25 N Copper and copper alloys (bronze, brass) machining alloy stock (1% Pb) brass, red bronze bronze 26 () lead-free copper and electrolytic copper thermosetting plastics 29 Non-metallic materials fiber-reinforced plastics 29 hard rubber 30 annealed Fe-based S Heat-resistant alloys hardened annealed hardened cast Fe-based Ni- or Co-based Ni- or Co-based HRC Ni- or Co-based N/mm² (350) 35 (320) Titanium alloys pure titanium alpha and beta alloys 36 R m 440* 37 R m 1050* H Tempered steel Chilled castings hardened and tempered hardened and tempered cast HRC HRC Tempered cast iron hardened and tempered HRC * R m = ultimate tensile strength, measured in MPa

25 Cutting data Grades, material 25 METRIC CTCP230 CTPP235 CTPM240 CTCK215 CTPK220 CTWN215 [m/min] [m/min] [m/min] [m/min] [m/min] [m/min] [m/min] [m/min] [m/min] [m/min] [m/min] [m/min] Grades, material metric The cutting data are non-binding indications for the operator. It is recommended to adapt them to the current conditions. Cutting data

26 2 26 Replacement parts Material Type, description /M8,0x30,0 Material Type, description Key size Torque moment [Nm] Torque moment [in.lbs] [lb] DMSD 3,2Nm/SORT 15IP IP ,3 Material Type, description Key size SD-T15IP-mm T15IP 4425 S4/SW4 SW4 Replacement parts Material Type, description l l Thread size Key size [mm] [in] M3,5X8,6-15IP/ M3,5 T15IP SUCCESS FACTORS: Technical Support In machining, we encounter hundreds of milling problems every day. Because we re the experts, and finding solutions and savings for you is what we do best. ROBERT BOKRAM Don t wait. Call us. We can help. Robert Bokram Product Manager Enduser Cutting Tools T F M ROBERT BOKRAM

27 The world of CERATZIT 27 Customized machining solutions for every customer. Outstanding performance under stress. Exceptional stability and hardness. Innovations in substrate materials, advanced coatings and cutting-edge geometries. All designed for your success. This is the world of CERATIZIT. The world of CERATIZIT Call us

28 MaxiMill 491: Engineered simplicity. Doing more with less effort, less waste, less power. That s the kind of innovation you can expect from us. Because creating new ways to help you thrive is what we do. Welcome to the world of CERATIZIT. Headquarters: CERATIZIT S.A. Route de Holzem 101 B.P. 51 L-8201 Mamer T F E. info@ceratizit.com Contact for further information: CERATIZIT USA, Inc Stephens Drive US-Warren, MI United States T F E. info.usa@ceratizit.com Your sales partner: CTUS MAXIMILL 491 CATALOG 2016