Tungaloy Report No. 415-E. Shoulder milling cutter NEW. Workhorse for rough machining operations!

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1 ungaloy Report No. 415E Shoulder milling cutter NEW Workhorse for rough machining operations!

2 pplication range of roughing series High ø5 ~ ø63 and work rigidity ø25 ~ ø5 ø2 ~ ø25 Low Light machining Heavy machining Suitable for roughing operations on B4 spindle ter machines 1 3 Optimum edge position prevents chatter High helix angle distributes and reduces the load for smoother cutting Best solution for preventing chip recutting Small inserts create small chips hrough tool air blast blows chips from the cutting area 2 4 Proven insert from standard range 4 cornered insert offers higher operating profit Positive rake chipbreakers MJ: for general purpose including exotic material J: for machining of aluminium Comparison of metal removal rate Optimum cutter design allows high productivity with large depth of cut Metal removal rate Q (cm 3 /min) Improved by 33%! ELD5R2M2.W2 Condition Work material S55C / C55 ool diameter ødc (mm) 2 Effective number of cutting edge line 2 3 Cutting speed Vc (m/min) 15 Feed per edge line fz (mm/t).1 Depth of cut (mm) 2 1 Width of cut ae (mm) 8 Vertical M/C B4 2

3 Versatile cutters for various work materials Optimized angular positioning prevents chatter Cutters with high insert density delivers higher productivity ir blast through tool blows off chips Proven insert from standard range Suitable for roughing operation of various materials ough cutting edge and low cutting force chipbreakers MJ: for general purpose MS: for stainless steel and exotic material machining J: for machining of aluminium Comparison of metal removal rate ELS11R32M32.W3 Condition Work material S55C / C55 ool diameter ødc (mm) 32 Effective number of cutting edge line 3 2 Cutting speed Vc (m/min) 1 Feed per edge line fz (mm/t).15 Depth of cut Width of cut (mm) ae (mm) Higher number of flutes guarantees high productivity Metal removal rate Q (cm 3 /min) Improved by 5%! Vertical M/C B5 New solution for roughing operations on large machines angential insert with tough edge allows high feed machining Highly rigid body, suitable for heavy machining Large core thickness increases body rigidity ir blast through tool to blow off chips Comparison of metal removal rate ough cutting edges provide stable machining even in heavy roughing operations Metal removal rate Q (cm 3 /min) Improved by 4%! Proven insert from standard range 4 cornered insert offers higher operating profit Condition Work material ool diameter ødc (mm) Effective number of cutting edge line Cutting speed Vc (m/min) LM11R5M22.E3 S55C / C Feed per edge line fz (mm/t).2 Depth of cut (mm) 5 4 Width of cut ae (mm) 3 2 Vertical M/C B5 3

4 Cutters ødc øds Shank type Cat. No. 9 Stock No. of eff. edge lines Lf ødc øds rs Lf L Max. ELD5R2M2.W with 1 SDM524PNMJ ELD5R25M25.W with 18 L R s Weight (kg) Replacement parts Description Cat. No. Clamping screw Wrench ir hole No. of inserts CSPB2L43 IP6DB SDH524FNJ rε Grades Cat. No. ccuracy Honing Coated Carbide H725 H14 H1 rε SDM524PNMJ M with SDH524FNJ H without Cutters ELD5 Standard cutting conditions Brinell hardness Cutting Speed Feed per tooth Work material HB Grades Vc (m/min) fz (mm/t) Low carbon steels (S15C / C15E4 etc.) < High carbon steels (S45C / C45 etc.) lloyed steels (SCM44 / 42CrMo4 etc.) H ool steels (SKD11 / X153CrMoV12 etc.) Stainless steels (SUS34 / X5CrNi189 etc.) < H Grey cast irons (FC25 / GG25 etc.) Ductile cast irons (FCD45 / GGG45 etc.) H luminium alloys (Si < 13%) luminium alloys (Si 13%) 2 5 H : Stocked items 4

5 Cutters Bore type Bore type R ødb ød a ødc b Lf Lf Rs L No. of eff. Weight ir No. of Cat. No. Stock edge lines ødc ødb ød r Lf b a Max. (kg) hole inserts LS11R5M22.E with 2 SM113..., SG ødc Description Cat. No. Cutter LS11R... ELS11R... Clamping screw Wrench Center bolt CSPB2.5 IP8D CM1X4H øds Cat. No. Stock No. of eff. Weight ir No. of edge lines ødc øds rs Lf L Max. (kg) hole inserts ELS11R25M25.W with 6 ELS11R32M32.W with 12 ELS11R4M42.W with 12 SM113 SG113 B B B 9º Shank type Replacement parts Shank type r Fig. 4 MJ r Fig. 5 MS Grades Cat. No. Coated Cermet Carbide She Cutters H725 H12 H13 H DS11 NS74 KS5F B rε SM1134PDPRMJ with.4 Fig.4 SM1138PDPRMJ with.8 Fig.4 SM11312PDPRMJ with 1.2 Fig.4 SM11316PDPRMJ M with 1.6 Fig.4 ELS11R SM1132PDPRMJ with Fig.4 LS11R SM1133PDPRMJ with 3. Fig.4 SM1134PDPRMS with.4 Fig.5 SG1134PDFRJ with.4 Fig.6 G SG1138PDFRJ with.8 Fig.6 ccuracy Honing Cautionary point in modifying cutter bodies r Fig. 6 J When using inserts with corner radius rε 2. mm, standard cutter bodies have to be modified R. From 2nd row onwards, please use insert with rε =.4 or.8 mm R Corner radius r ε (mm) he dimension of modifying (mm) No modification required : Stocked items 5

6 Standard cutting conditions Work material Brinell fz (mm/t) hardness Priority Grade Cutting HB Vc (m/min) Feed per tooth MJ MS J Low carbon steels First choice H725 (S15C / C15E4 etc.) < 2 For wear resistance High carbon steels and lloyed steels First choice H (S55C / C55, SCM44 / 42CrMo4 etc.) For wear resistance 313 ool Steel First choice H (SKD11 / X153CrMoV12 etc.) For wear resistance Stainless steel (SUS34 / X5CrNi189 etc.) H Grey cast iron First choice H (FC25 / GG25 etc.) For wear resistance Ductile cast iron First choice H12 (FCD45 / GGG45 451S etc.) etc.) For wear resistance luminium alloys (Si (Si < < 13%) 13%) DS luminium alloys (Si (Si 13%) itanium alloys (i6i4v etc.) etc.) Heat resistant alloys (Inconel718 etc.) DS H H Cutters ødb ød a b R Bore type ødc Lf 9º Replacement parts Description Cat. No. pplicable cutter Clamping screw orx bit Grip Mono block type substitution wrench LM11R5 LM11R63 CSB3.5L11 B15S HB 15 Center bolt SD63 SD898 No. of eff. Cat. No. Stock Weight No. of edge ødc ødb ød r Lf b a Max. ir lines (kg) hole inserts LM11R5M22.E with 21 LM11R63M27.E with 32 LM11R63M with 32 Wrench LMMU117**PNER MJ B rε 6 Stock Cat. No. ccuracy Honing Coated grades Cutters H H14 H B rε LMMU1178PNERMJ M with LMMU11716PNERMJ M with LMMU11724PNERMJ M with LM11 LMMU11732PNERMJ M with : Stocked items

7 Standard cutting conditions Brinell Work material hardness Priority Grade Cutting speed Feed per tooth HB Vc (m/min) fz (mm/t) First choice H Low carbon steels Low (S15C carbon / C15E4 steels etc.) (S15C / C15E4 etc.) < 2 Priority for impact resistance H Priority for wear resistance High carbon steels High (S45C carbon / C45 etc.) steels (S45C / C45 etc.) 2 3 lloyed steels 15 3 (SCM44 / 42CrMo4 etc.) ool steels ool (SKD61/ steels X4CrMoV51 (SKD61/ X4CrMoV51 etc.) etc.) < 3 Practical examples First choice H Priority for impact resistance H Priority for wear resistance First choice H Priority for impact resistance H Priority for wear resistance First choice H Priority for impact resistance H Priority for wear resistance Stainless steels First choice H (SUS34 / X5CrNi189 etc.) Grey cast irons First choice H12 Grey (FC25 cast / 25 irons etc.) (FC25 / GG25 etc.) Priority for wear resistance Ductile cast irons First choice H12 (FCD45 / 451S GGG45 etc.) Priority for wear resistance 1115 Heatresisting alloy First choice (Inconel 718 / i6l4v H etc.) From 2nd row onwards, please use insert with rε =.8 mm Work piece type Cutter Insert Grade Cover of machine part ELD5R2M2.W2 (ø2, z = 2) SDM524PNMJ LS11R5M22.E4 (ø5, z = 4) SM1138PDPRMJ H725 H725 SCM44 / 42CrMo4 SS4 / E275 Work material 12 mm 4 mm Cutting conditions Cutting speed: Vc (m/min) Feed per tooth: fz (mm/t) Feed speed: Vf (mm/min) Depth of cut: (mm) Width of cut: ae (mm) Method of machining Coolant passes 4 5 Shoulder milling Shoulder milling Wet Dry Flexible machine B4 Vertical M/C B5 Results 2.5 Machining 2. time 1.5 reduced 2%! 1..5 Higher productivity achieved than with competitor solid end mills. Reduction of inventory with the reduction of regrinding costs. Machining time (min) Metal removal rate Q cm 3 /min Productivity 1.3 times! ungrec can machine at a 3% higher table speed with no chatter, even when machining on machine tools and components with low rigidity levels. 7

8 Work piece type Cutter Insert Grade Power generator part Base of machine LS11R5M22.E4 (ø5, z = 4) LM11R5M22.E3 (ø5, z = 3) SM1138PDPRMJ LMMU1178PNERMJ H725 H12 Inconel 718 FC25 / GG25 Work material 42 mm 4 mm Cutting conditions Cutting speed: Vc (m/min) Feed per tooth: fz (mm/t) Feed speed: Vf (mm/min) Depth of cut: (mm) Width of cut: ae (mm) Method of machining Coolant Shoulder milling Shoulder milling Wet Dry Horizontal M/C B5 Vertical M/C B5 Results Machining time (min) Machining time reduced 6%! Machining with large depth of cut with ungrec can drastically reduce machining time. chieves stable tool life due to no chipping on cutting edges. Metal removal rate Q cm 3 /min Productivity 1.6 times! ecmill allows more stable machining without chipping on the cutting edges, this improves productivity by 6%. ungaloy Corporation (Head office) 111 YoshimaKogyodanchi Iwakicity, Fukushima, Jan Phone: Fax: ungaloy merica, Inc. Phone: Fax: ungaloy Canada Phone: Fax: ungaloy de Mexico S.. Phone: Fax: ungaloy do Brasil Comércio de Ferramentas de Corte Ltda. Phone: Fax: ungaloy Germany GmbH Phone: Fax: ungaloy France S..S. Phone: Fax: ungaloy Italia S.r.I. Phone: Fax: ungaloy Czech s.r.o Phone: Fax: ungaloy Ibérica S.L. Phone: Fax: ungaloy Scandinavia B Phone: Fax: ungaloy Rus, LLC Phone: Fax: ungaloy Polska Sp. z o.o Phone: Fax: ungaloy U.K. Ltd Phone: Fax: ungaloy Hungary Kft Phone: Fax: ungaloy urkey Phone: Fax: ISO 91 certified ISO 141 certified QCJ56 EC97J1123 ungaloy Corporation ungaloy Group Jan site and sian production site 18/1/ /11/1997 Distributed by: ungaloy Cutting ool (Shanghai) Co.,Ltd. Phone: Fax: ungaloy Cutting ool (hailand) Co.,Ltd. Phone: Fax: ungaloy Singore (Pte.),Ltd. Phone: Fax: ungaloy India Pvt. Ltd. Phone: Fax: ungaloy Korea Co., Ltd Phone: Fax: ungaloy Malaysia Sdn Bhd Phone: Fax: ungaloy ustralia Pty Ltd Phone: Fax: P. ungaloy Indonesia Phone: Fax: Produced from Recycled per Dec. 212 (J)