UNION TOOL UDC SERIES for Cemented Carbide. Copyright 2013 UNION TOOL CO. All rights reserved

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1 UNION TOOL UDC SERIES for Cemented Carbide

2 CONTENTS Features of UDC series, patented Diamond Coating. Close study of milling Cemented Carbide. NEW drilling technology BONUS data

3 UDC SERIES TARGET HARDNESS MOLD TARGET UDC SERIES DIAMOND COATING NEW Cemented Carbide Changing to Cemented Carbide(Longer hit life) Shorten the lead-time by direct milling Cost down by using Tungsten Carbide End Mills HARDENED STEEL PRE-HARDENED STEEL Current Stage HARD MAX COATING UT COATING Direct milling on Cemented Carbide is now available!!

4 UDC SERIES UDC DIAMOND COATING Hardness: 9000Hv High adhesion & Wear resistance Special Diamond Coating UDC coating made by Thermal CVD method Super high Adhesion and Wear resistance Controlled micro structure Improves both Hardness and Durability Comparison of Adhesion / Wear resistance using shot-blast test [Standard] Grain size: Normal Hardness: Normal Controlled Diamond coating micro structure [High Wear Resistance] Grain size: Large Hardness: High [Smooth surface] Grain size: Small Hardness: Low Improves Hardness & Durability Relative blasting life 300% 250% 200% 150% 100% 50% 0% Blasting Test / Adhesion and wear resistance of the film UT Measure time until coating peeling off by shot blast. Competitor Standard UDC 5 Layser coating A B C D

5 UDC SERIES UDC DIAMOND COATING Required Characteristics Toughness Original coating process with excellent controlled micro-structure offers outstanding toughness. Hardness Our original SP3 structure has similar hardness to diamond. Adherence UNION TOOL original pre-treatment process and coating process offers extreme adherence.

6 UDC SERIES VARIATION

7 CONTENTS Features of UDC series, patented Diamond Coating. Close study of milling Cemented Carbide. NEW drilling technology BONUS data

8 CARBIDE MILLING CUTTING CHIP Material: 90HRA (CIS VM-40) Cemented Carbide UDCB Series Process Tool Spindle speed [min -1 ] XY Feed [mm/min] ap [mm] Coolant Roughing UDCB (R0.5) 30, Air blow

9 CARBIDE MILLING HEXALOBULAR Coolant: Air Blow Milling Time: 39min Work Size: φ9 mm x Depth 2.2mm Material: 92.5HRA (CIS VF20) Cemented Carbide UDCB Series Material Removal Rate = 91.7mm 3 Process Roughing Tool UDCB (R0.5) Spindle speed [min -1 ] XY Feed [mm/min] Approach Feed [mm/min] ap [mm] ae [mm] Milling time [min] 30, * *Bottom surface ae amount = 0.05mm

10 CARBIDE MILLING DEEP HEXALOBULAR Coolant: Air Blow Milling Time: 156min Work Size: φ9 mm x Depth 6.0mm Material: 92.5HRA (CIS VF20) Cemented Carbide UDCLB Series Material Removal Rate = 274.4mm 3 Process Tool Spindle speed [min -1 ] XY Feed [mm/min] Approach Feed [mm/min] ap [mm] ae [mm] Milling time [min] Roughing UDCLB (R0.5 x 2.5mm) Roughing UDCLB (R0.5 x 5.0mm) 30, Finishing UDCLB (R0.5 x 5.0mm)

11 CARBIDE MILLING Mirror Surface Coolant: Air Blow (Roughing) Oil Mist (Finishing) Work Size: 10mm x 8mm x 18mm Material: 90HRA (CIS VM-40) Cemented Carbide UDCLRS Series SIDE Ra: 0.069μm Rz: 0.535μm BOTTOM Ra: 0.010μm Rz: 0.078μm Material Removal Rate = 144mm 3 Process Tool Spindle speed [min -1 ] XY Feed [mm/min] ap [mm] ae [mm] Roughing UDCLRS (φ2 CR0.05 x 2mm) 20, Finishing UDCLRS (φ2 CR0.05 x 2mm) 20, (Bottom) 0.9 (Side)

12 CARBIDE MILLING Transcription CR0.05 Work Bottom Corner Radius transcription CR0.1 CR0.1 CR0.03 Material: 90HRA (CIS VM-40) Cemented Carbide Slotting Depth: 4mm Work Size: 20mm x 20mm x 10mm UDCLRS (φ2 CR0.1 x4mm) UDCLRS (φ2 CR0.05 x4mm) UDCLRS (φ2 CR0.03 x4mm) *Used 1pc each for roughing and finishing on each size. CR0.05 CR0.03 Material Removal Rate = 176mm 3 Tool Spindle speed [min -1 ] XY Feed [mm/min] ap [mm] UDCLRS 20, Coolant Air blow Milling Time [min] 30 *Bottom surface ap = 0.01mm

13 CARBIDE MILLING Accuracy Measuring data on each label Actual Outer Diameter Max/Min rate of Ball Radius tolerance Max/Min rate of Corner Radius tolerance

14 CARBIDE MILLING CERAMICS Material: Alumina (Al 2 O 3 ) Material: Zirconia (ZrO 2 (3mol%Y 2 O 3 )) Tools after milling 10mm³ Alumina Zirconia Alumina Zirconia Tool Life Material Removal Rate (mm³] Tool Spindle speed [min -1 ] XY Feed [mm/min] ap [mm] ae [mm] Coolant UDCB (R0.5 x 0.7) *Bottom surface ae amount = 0.03mm 20, Air blow

15 CARBIDE MILLING COOLANT Tools after milling 10hr 30min Water Soluble coolant Material: 90HRA (CIS VM-40) Cemented Carbide Air Blow (Nozzle) Use Air Blow for best result! Tool Spindle speed [min -1 ] XY Feed [mm/min] ap [mm] ae [mm] Coolant Milling Time [h: m] UDCB (R0.5 x 0.7) 20, Air blow / Water Soluble 10:30 *Bottom surface ae amount = 0.03mm

16 UDC SERIES SPINDLE SPEED Vf100 Vf200 Vf300 [Milling condition] Tool: R1.0 Ball type (UDCB ) Work Material: G3(VM-40) 90HRA ap: 0.1mm ae: 0.3mm Coolant: Oil Mist Milling time: 6.53min/pc MRA: 20mm³ MRR & Efficiency Testing Result ( R1 tool with Vc= 27 ~82m/min ) No difference found on Tool Life or Tool Damage. Higher spindle speed improves the efficiency. MRR (%) 27.4m/min = 100% Efficiency Velocity(m/min) Efficiency (vfxapxae) mm³/min

17 CONTENTS Features of UDC series, patented Diamond Coating. Close study of milling Cemented Carbide. NEW drilling technology BONUS data

18 UDCMX DIAMOND COATED DRILLS 7 models Diameter tolerance: 0/-0.02 Long hit life with UDC coating. Thinning improves biting performance and hole straightness. Higher rigidity and excellent chip evacuation offered with optimum cutting geometries.

19 CARBIDE DRILLING φ0.4 [Blind hole] Coolant: Air Blow [nozzle] Hole depth: 2.8mm x 100 holes Work size: 20mm x 20mm x 3mm Drilling Time: 36 sec/hole Material: 90HRA (CIS VM40) Cemented Carbide Holes around on 100 hits 1mm Tool after 100 hits Possible to use continuously. Process Drilling Tool UDCMX ( 0.4mm x 4mm) Spindle speed [min -1 ] Feed [mm/min] Step Amount [mm] Hole Depth [mm] Drilling time [sec] 20,000 5 Non-Step 2.8mm 36/hole *Bottom surface ae amount = 0.05mm

20 UDCMX DRILLS COOLANT [Drilling condition] Drill: 0.6mm (Prototype) Work Material: VM-40 (90HRA) N: 20,000min -1 Vf: 5mm/min Step amount: 0.05mm Number of holes [0.6mm] Drilling Depth : 4.5mm Drilling time : 3min 10sec / hole Air Blow Oil Mist Water Soluble Use Air Blow for best result!

21 UDCMX DRILLS COOLANT [Drilling condition] Drill: 0.6mm (Prototype) Work Material: VM-40 (90HRA) N: 20,000min -1 Vf: 5mm/min Step amount: 0.05mm Drilling Depth : 4.5mm Drilling time : 3min 10sec / hole Air Blow Oil Mist Water Soluble

22 CARBIDE DRILLING φ1.0 x 10mm Coolant: Air Blow [nozzle] Work size: 20mm x 20mm x 10mm Drilling Time: total 86 min Material: 90HRA (CIS VM40) Cemented Carbide Cross Section Blind holes Depth : 2mm 4mm 6mm 8mm 10mm Through hole Process Tool Spindle speed [min -1 ] Feed [mm/min] Step Amount [mm] Hole Depth [mm] Drilling UDCMX ( 1.0mm x 10mm) 20, , 4, 6, 8, 10

23 CONTENTS Features of UDC series, patented Diamond Coating. Close study of milling Cemented Carbide. NEW drilling technology BONUS data

24 CARBIDE MILLING Deep Milling φ Material: 90HRA (CIS VM-40) Cemented Carbide Tool after used UDCB Series Material Removal Rate = 1,400mm 3 Tool UDCB (R3 x 4.2) Spindle speed [min -1 ] XY Feed [mm/min] ap [mm] ae [mm] Coolant Milling Time [min] 20, Air blow 52

25 CARBIDE MILLING Circular Pocket Material: 90HRA (CIS VM-40) Cemented Carbide Work Size : φ6.35 x 4.2mm UDCB Series Material Removal Rate = 100mm 3 /pc [ total 1,300mm 3 ] Tool UDCB (R3 x 4.2) Spindle speed [min -1 ] XY Feed [mm/min] ap [mm] ae [mm] Coolant Milling Time [min] 20, Air blow 3/pc

26 CARBIDE MILLING Pocket Milling Material: 92.5HRA (CIS VF-20) Cemented Carbide Tool after used UDCB Series Material Removal Rate = 2,800mm 3 Tool UDCB (R3 x 4.2) Spindle speed [min -1 ] XY Feed [mm/min] ap [mm] ae [mm] Coolant Milling Time [min] 20, Air blow 137

27 CARBIDE MILLING Hexagonal Pyramid Material: 92.5HRA (CIS VF-20) Cemented Carbide Work Size : 10.2x 1.39mm Tool after used UDCB Series Material Removal Rate = 72.6mm 3 Tool Spindle speed [min -1 ] XY Feed [mm/min] ap [mm] ae [mm] Coolant Milling Time [min] UDCB (R0.5 x 0.7) *Bottom surface ae amount= 0.03mm 30, Air blow 36

28 UDC SERIES CAUTION CLAMP NG CLAMP OK Do NOT clamp diamond coated area on shank part into the tool holder. Tool may stuck inside especially with shrink-fit type holder.

29 U.S. UNION TOOL, INC. U.S. UNION TOOL, INC. (U.S. HEADQUARTERS) 1260 N.Fee Ana Street, Anahaim, CA TEL: FAX: UPPER MIDWEST REGIONAL SERVICE CENTER (Customer Service, Minneapolis, Minnesota) 155 Bridgepoint Drive, Unit 3 South St.Paul, MN TEL: FAX: NORTHERN CALIFORNIA REGIONAL SERVICE CENTER (Customer Service, Santa Clara, California) 2962 Scott Boulevard, Santa Clara, CA TEL: FAX: