Profile Milling Program Tools

Transcription

1 Profile Milling Program Tools Small Ball Nose & Back raft Inserts VRBS 2 imensions R XRN TN HSN escription VRBS Used for semi and finish-milling small radius or detail work, VRBS and surface milling in soft and herd steel, cast iron, aerospace and non-ferrous alloys, graphite, etc. Suitable for high speed and hard milling. VB imensions R XRN TN HSN 1 R VB Used for semi and finish-milling small radius or detail work, VB and surface milling in soft and herd steel, cast iron, aerospace and non-ferrous alloys, graphite, etc. Suitable for high speed and hard milling. VRBS, VB, HF Inserts HF Cutting Recommendations Inch High Feed Inserts HF imensions PR XRN TN HSN escription HF Millstar HF insert is designed for High feed and High speed HF machining. It runs at high cutting speed and feed rates with shallow depth of cut. It allows the chip to flow up and out of the HF cut quickly. It allows heavy chip loads. HF HF Cutting Recommendations for High Feed Inserts Work Material USA/W.- Nr./JIS SK61 SK61 SK61 SK12 SK12 SK12 Material Hardness Cutting epth at iameter ap max Cutting Width Cut speed at Max feed per tooth fz at cutting insert diameter Coating Insert Type Hrc Ae max Recom. sfm/min < % HF XRN/HSN ~ ~ ~ ~ ~ % HF XRN/HSN ~ ~ ~ ~ ~ % HF HSN ~ ~ ~ ~ ~.04 < % HF XRN/HSN ~ ~ ~ ~ ~ % HF XRN/HSN ~ ~ ~ ~ ~ % HF HSN ~ ~ ~ ~ ~.04 P20/1,2330 < % HF XRN/HSN ~ ~ ~ ~ ~.04 P20/1, % HF XRN/HSN ~ ~ ~ ~ ~.04 2/1,2379/ SK11 < % HF XRN/HSN ~ ~ ~ ~ ~.04 2/1,2379/ SK % HF XRN/HSN ~ ~ ~ ~ ~.04 2/1,2379/ SK % HF HSN ~ ~ ~ ~ ~.04 Grey Cast Iron/ GG < % HF XRN/HSN ~ ~ ~ ~ ~.04 Cast Iron/GGG % HF XRN/HSN ~ ~ ~ ~ ~ Page 20

2 Small Ball Nose & Back raft Inserts VRBS 2 imensions R XRN TN HSN escription VRBS 6 6 8,10 3 Used for semi and finish-milling small radius or detail VRBS 8 8 4,50 4 work, and surface milling in soft and herd steel, cast iron, aerospace and non-ferrous alloys, graphite, etc. Suitable for high speed and hard milling. VB imensions R XRN TN HSN 1 R VB ,6 0,1/0,4 Used for semi and finish-milling small radius VB ,1/0,4 or detail work, and surface milling in soft and herd steel, cast iron, aerospace and non-ferrous alloys, graphite, etc. Suitable for high speed and hard milling Metric High Feed Inserts HF imensions PR XRN TN HSN escription HF ,00 Millstar HF insert is designed for High feed and High HF ,43 speed machining. It runs at high cutting speed and feed rates with shallow depth of cut. It allows the chip to flow HF ,94 up and out of the cut quickly. It allows heavy chip loads. HF ,26 HF ,82 Cutting Recommendations for High Feed Inserts Work Material USA/W.-Nr./ JIS SK61 SK61 SK61 SK12 SK12 SK12 Material Hardness Cutting epth at iameter ap max Cutting Width Cut speed at Max feed per tooth fz at cutting insert diameter Coating Insert Type Hrc Ae max Recom. m/min <41 0,4 0,48 0,64 0,8 1 75% HF XRN/HSN ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1, ,4 0,48 0,64 0,8 1 75% HF XRN/HSN ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1, ,3 0,4 0,48 0,64 0,8 75% HF HSN ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1,0 <41 0,4 0,48 0,64 0,8 1 75% HF XRN/HSN ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1, ,4 0,48 0,64 0,8 1 75% HF XRN/HSN ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1, ,3 0,4 0,48 0,64 0,8 75% HF HSN ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1,0 P20/1,2330 <41 0,4 0,48 0,64 0,8 1 75% HF XRN/HSN ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1,0 P20/1, ,4 0,48 0,64 0,8 1 75% HF XRN/HSN ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1,0 2/1,2379/ SK11 <41 0,4 0,48 0,64 0,8 1 75% HF XRN/HSN ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1,0 2/1,2379/ SK ,4 0,48 0,64 0,8 1 75% HF XRN/HSN ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1,0 2/1,2379/ SK ,3 0,4 0,48 0,64 0,8 75% HF HSN ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1,0 Grey Cast Iron/ GG <41 0,4 0,48 0,64 0,8 1 75% HF XRN/HSN ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1,0 Cast Iron/GGG 41+ 0,4 0,48 0,64 0,8 1 75% HF XRN/HSN ,25~0,5 0,3~0,55 0,4~0,71 0,5~0,89 0,56~1,0 VRBS, VB, HF Inserts HF Cutting Recommendations Metric Page 21 21

3 Copy Milling Program Tools Insert Coatings Flat Bottom, Back raft & Toroid Inch Inserts Inch Flat Bottom, Back raft, Toroid B-N imensions R XRN TN HSN escription R B 0375 N /32,1/16 Precision ground with 7º back taper. Used for milling of cores, cavities, filets B 0500 N /32,1/16 B 0625 N /32,1/16 with straight or very steep walls of harder materials. B 0750 N /32,1/16,1/8 B 1000 N /32,1/16,1/8 B 1250 N /32,1/16,1/8 B-R R XRN TN HSN escription R B 0375 R /32 Precision ground with positive ground B 0500 R /32,1/16,1/8 chip-breaker and 7º back B 0625 R /32,1/16 taper. Used for milling of cores, cavities, filets B 0750 R /32,1/16,1/8 with straight or very B 1000 R /32,1/16,1/8 steep walls of softer materials. B 1250 R /32,1/16,1/8 BS R 1 XRN TN HSN escription BS 0375 N /32,1/ Precision ground with unique crossover design between flat BS 0500 N ,1/32,1/ bottom FB and back draft B BS 0625 N /32,1/ inserts. Allows straight walls with a larger step down than BS 0750 N /32,1/16,1/ B. Allows higher BS 1000 N /32,1/16,1/ cutting speeds and feeds. FB-R R XRN TN HSN escription FB 0375 R /32 Precision ground R with positive ground FB 0500 R /32,1/16,1/8 chip-breaker. Flat bottom FB 0625 R /32,1/16 inserts for shoulder milling, fillet finishing and long FB 0750 R /32,1/16,1/8 reach angular wall FB 1000 R /32,1/16,1/8 finishing of softer materials. FB 1250 R /32,1/16,1/8 TO R XRN TN HSN escription R TO Precision ground large corner radius & back TO taper for spiral and packet milling. Milling of pre-hard TO and hardened flat surfaces at higher speeds than tools TO with smaller corner radii. TO Good choice for HS milling of Aluminum. TO TOB-NF R XRN TN HSN escription R TOB 0500-NF Millstar inserts designed for high seed high feed TOB 0625-NF roughing of Aluminum, but TOB 0750-NF also has the versatility to be used for fine finishing TOB 1000-NF as well. NA Non-coated grade. The lowest cost choice. May be used at normal speeds, or lower speeds on older machines, for all purpose milling. May be resharpened or altered. XRN Multi-layer hybrid coating of AlTiCrN. This coating has very good heat resistance and also a low friction coefficient. The XRN coating is designed for use in HSM of un-heat treated softer materials such as Titanium, Inconel, Stainless Steels and other gummy materials that require the use of liquid coolant. HSN Millstar s new coating is a multi-layer hybrid Nano coating. This new coating has very good heat resistance and high hardness. The HSN coating is designed for use in HSM of Heat Treated materials up to 72 HRc Customers using our new HSN coating are seeing average tool life increases of 3-4 times more than the competition. Tool life increases as much as 10 times have been documented. 22 Radius Ordering s: For.015 use ordering #.015 For 1/32 use ordering # 02 1/16 use ordering # 04 For 1/8 use ordering # 08 Example: 1/2 BS-0500N-04-HSN Page 22

4 ATiN-EXAON (TN) Titanium Aluminum Nitride advanced PV coating. A special, improved ATiN coating approaching surface hardness of CBN on a tough substrate. Recommended for tough and hard metal machining applications. When high cutting temperatures are encountered the coating acts as a heat barrier, protecting the cutting edge. This allows for aggressive, high speed and dry milling so often encountered in today s die and mold machining. Use on tool, die and higher alloy steels, especially at hardness over 40 HRc. Also appropriate for all stainless steels (300, 400 and PH series), nickel alloys, titanium, nodular and gray cast iron. Also useful in machining carbon graphite. M iamond coating. Custom coating for cutting nonferrous, non-metallic and very abrasive materials at highly elevated speeds. Use on copper, bronze, brass, aluminum-silicon alloys, carbon graphite, solid and fiber-reinforced plastics, ceramics and composite materials. Custom tool coatings for specific applications are available by request. Flat Bottom, Back raft, Toroid B-N R Tool Ordering imensions R XRN TN HSN escription B 10 N 10 8,5 0,5/0,8/1 Precision ground with 7º back taper. Used for milling B 12 N 12 9,95 0,5/1/2 of cores, cavities, filets with B 16 N 16 11,55 0,5/1/1,3/2/3 straight or very steep walls of harder materials. B 20 N 20 13,35 0,5/1/1,6/2/3 B 25 N 25 19,95 1/2 B 32 N 32 8,5 1,0/2,6 B-R R XRN TN HSN escription B 10 R 10 8,5 0,5/0,8/1 Precision ground with R positive ground B 12 R 12 9,95 0,5/1 chip-breaker and 7º back B 16 R 16 11,55 0,5/1/1,3 taper. Used for milling of cores, cavities, filets B 20 R 20 13,35 0,5/1/1,6 with straight or very B 25 R 25 19,95 1/2 steep walls of softer materials. B 32 R 32 23,35 2,6 BS R 1 XRN TN HSN escription BS 10 N 10 8,5 0,1/0,8/1,0 3 Precision ground with unique crossover design between flat BS 12 N 12 9,95 0,1/1 3 bottom FB and back draft B BS 16 N 16 11,55 0,1/1/1,3 3 inserts. Allows straight walls with a larger step down than BS 20 N 20 13,35 0,1/1/1,6 3 B. Allows higher BS 25 N 25 19,95 1/2 3 cutting speeds and feeds. FB-R R XRN TN HSN escription R FB 10 R 10 8,5 0,8 Precision ground with positive ground FB 12 R 12 9,15 1 chip-breaker. Flat bottom FB 16 R 16 10,65 0,5/1,3 inserts for shoulder milling, fillet finishing and long FB 20 R 20 12,25 1,6 reach angular wall finishing FB 25 R 25 16,35 2 of softer materials. FB 32 R 32 21,3 2,6 TO R XRN TN HSN escription TO ,65 3 Precision ground large R corner radius & back taper TO ,20 3 for spiral and packet milling. TO ,25 4 Milling of pre-hard and hardened flat surfaces at TO ,15 5 higher speeds than tools TO ,25 6 with smaller corner radii. Good choice for HS milling TO ,15 7,5 of Aluminum. TO ,95 8 TOB-NF R XRN TN HSN escription TOB 12-NF 12 9,2 3 Millstar inserts designed R for high seed high feed TOB 16-NF 16 11,25 3 roughing of Aluminum, but TOB 20-NF 20 13,15 3 also has the versatility to be used for fine finishing TOB 25-NF 25 18,25 3 as well. Flat Bottom, Back raft & Toroid Metric Inserts Metric Page 23 23

5 Copy Milling Program Tools PC-CBN Tipped Back raft BS Tool Ordering imensions R 1 XRN TN HSN escription BS 0375 N /32,1/ Precision ground with unique crossover design between BS 0500 N ,1/32,1/ flat bottom FB and back draft B inserts. Allows straight BS 0625 N /32,1/ walls with a larger step down BS 0750 N /32,1/16,1/ than B. Allows higher cutting speeds and feeds. BS 1000 N /32,1/16,1/ PC Tipped For carbon milling with longer tool life CBN Tipped For high speed machining or milling of high hardness materials with longer tool life and superior finishes. Inch Back raft PC & CBN Tipped 24 Radius Ordering s: For.015 use ordering #.015 For 1/32 use ordering # 02 1/16 use ordering # 04 For 1/8 use ordering # 08 Example: 1/2 BS-0500N-04-PC or CBN Page 24

6 Back raft BS Tool Ordering imensions R 1 XRN TN HSN escription BS 10 N 10 8,5 0,1/0,8/1,0 3 Precision ground with unique crossover design BS 12 N 12 9,95 0,1/1 3 between flat bottom FB and back draft B inserts. BS 16 N 16 11,55 0,1/1/1,3 3 Allows straight walls with a BS 20 N 20 13,35 0,1/1/1,6 3 larger step down than B. Allows higher BS 25 N 25 19,95 1/2 3 cutting speeds and feeds. Metric Back raft PC & CBN Tipped Page 25 25

7 Copy Milling Program Tools Inserts Coatings Ball Nose Inserts Ball Nose Inserts BS-N S imensions S XRN TN HSN escription BS 0375 N Sidecutting, non-chipbreaker. Side cutting insert used in BS 0500 N cavity and core profiling, for BS 0625 N blending of fillets on medium and hard materials. BS 0750 N BS 1000 N BS 1250 N MB XRN TN HSN escription MB Unique cutting edge allows performance in all operations in MB material below 42 HRc; in semi, & finishing operations above. MB Significant benefits in chip evacuation. Insert geometry MB allows smoother cutting MB motion-diminishing heat build up & tool deflection, reduces MB vibration caused by cutting action. MBT XRN TN HSN escription MBT Precision ground, harder grade, for semi-finish and finish MBT milling. Excellent choice for MBT unattended finish milling at small depth and high speeds MBT and feed rates. MBT MBT RB-N XRN TN HSN escription RB 0375 N Precision ground, non-chipbreaker. Best choice RB 0500 N for cavity, core and profile RB 0625 N milling of pre-hard and fully hard die/mold steels, RB 0750 N cast steels and cast iron. RB 1000 N Strongest cutting edge design. RB 1250 N Inch NA Non-coated grade. The lowest cost choice. May be used at normal speeds, or lower speeds on older machines, for all purpose milling. May be resharpened or altered. XRN Multi-layer hybrid coating of AlTiCrN. This coating has very good heat resistance and also a low friction coefficient. The XRN coating is designed for use in HSM of un-heat treated softer materials such as Titanium, Inconel, Stainless Steels and other gummy materials that require the use of liquid coolant. HSN Millstar s new coating is a multi-layer hybrid Nano coating. This new coating has very good heat resistance and high hardness. The HSN coating is designed for use in HSM of Heat Treated materials up to 72 HRc Customers using our new HSN coating are seeing average tool life increases of 3-4 times more than the competition. Tool life increases as much as 10 times have been documented. 26 Page 26

8 ATiN-EXAON (TN) Titanium Aluminum Nitride advanced PV coating. A special, improved ATiN coating approaching surface hardness of CBN on a tough substrate. Recommended for tough and hard metal machining applications. When high cutting temperatures are encountered the coating acts as a heat barrier, protecting the cutting edge. This allows for aggressive, high speed and dry milling so often encountered in today s die and mold machining. Use on tool, die and higher alloy steels, especially at hardness over 40 HRc. Also appropriate for all stainless steels (300, 400 and PH series), nickel alloys, titanium, nodular and gray cast iron. Also useful in machining carbon graphite. M iamond coating. Custom coating for cutting nonferrous, non-metallic and very abrasive materials at highly elevated speeds. Use on copper, bronze, brass, aluminum-silicon alloys, carbon graphite, solid and fiber-reinforced plastics, ceramics and composite materials. Custom tool coatings for specific applications are available by request. Ball Nose Inserts BS-N imensions S XRN TN HSN escription BS 10 N 10 9,50 3,65 Sidecutting, non-chipbreaker. Side cutting insert used in BS 12 N 12 8,80 2,90 cavity and core profiling, for BS 16 N 16 10,70 2,85 S BS 20 N 20 12,75 2,85 blending of fillets on medium and hard materials. BS 25 N 25 17,20 4,85 BS 30 N 30 20,00 5,10 BS 32 N 32 21,00 5,30 MB XRN TN HSN escription MB ,65 Unique cutting edge allows performance in all operations in MB ,20 material below 42 HRc; in semi, MB ,25 & finishing operations above. MB ,15 Significant benefits in chip evacuation. Insert geometry MB ,25 allows smoother cutting MB ,15 motion-diminishing heat build up & tool deflection, MB ,95 reduces vibration caused by cutting action. MBT XRN TN HSN escription MBT ,65 Precision ground, harder grade, for semi-finish and finish MBT ,20 milling. Excellent choice for MBT ,25 unattended finish milling at small depth and high speeds MBT ,15 and feed rates. MBT ,25 MBT ,15 MBT ,95 RB-N XRN TN HSN escription RB 10 N 10 9,50 Precision ground, non-chipbreaker. Best choice RB 12 N 12 9,20 for cavity, core and profile RB 14 N 14 9,45 milling of pre-hard and fully hard die/mold steels, cast RB 16 N 16 11,25 steels and cast iron. Strongest RB 20 N 20 13,15 cutting edge design. RB 22 N 22 17,45 RB 25 N 25 18,25 RB 30 N 30 22,15 RB 32 N 32 21,95 Metric Ball Nose Inserts Page 27 27