YE-EI10 Ball Corner Radius Ball Corner Radius INSERTS & STEEL / CARBIDE HOLDERS HEAD OFFICE 68, Cheongcheon-Dong, Bupyeong-Gu, Incheon 4-0, KOREA PHONE :+82--526-09, FAX:+82--526-4373 Http://www.yg1.kr E-mail:yg1@yg1.kr INSERTS & STEEL / CARBIDE HOLDERS YG1EI103
INDEX / CASE STUDY INDEX / CASE STUDY ITEM MODEL DESCRIPTION PAGE Carbon Steels Alloy Steels Tool Steels Cast lron Hardened Steels Stainless Steels Aluminum ~HRc HRc~ ~HRc HRc~ ~HRc HRc~ ~HRc HRc~ ~HRc28 ~HRc8 XMBA i-xmill BALL INSERT for GENERAL PURPOSE 4 XMB0C i-xmill BALL INSERT for HARDNESS STEEL 4 ZBT / ZBS i-xmill BALL HOLDERS - STEEL 5 ZBC i-xmill BALL HOLDERS - CARBIDE 6 XMRA i-xmill CORNER RADIUS INSERTS for GENERAL PURPOSE 7 XMR0C i-xmill CORNER RADIUS INSERTS for HARDNESS STEEL 7 ZRT / ZRS i-xmill CORNER RADIUS HOLDERS - STEEL 9 S 10 : Excellent, : Good CASE STUDY (BALL) CASE STUDY (CORNER RADIUS) YG-1 (Total Milling Length 189m) YG-1 (Total Milling Length 4m) 0 0 Competitor A (Total Milling Length 189m) Competitor A (Total Milling Length 4m) 1 Competitor B (Total Milling Length 189m) Competitor B (Total Milling Length 4m) 0 0 1 0 4 Tools :i -Xmill Ball (XMB0C0) Size : Ø Work Material : JIS : SKD61 (HRc), DIN : X40GrMoV51(1.2344) AISI : H Cutting Speed : 80.42 m/min. R.P.M : 00 rev./min. Feed : 3 mm/min. Feed per tooth :0. mm/tooth Milling Method : Side Cutting Milling Depth : Axial : 0.8 mm Radial : 1.6 mm Coolant : Oil Mist Overhang : YG-1, Competitor B : 48 mm Competitor A : 56 mm Machine : Machining Center Tools : i-xmill Corner Radius (XMRA0) Size : Ø x Work Material : KS : KP4M (Mold steels HRc) DIN : 40CrMnNiMo8-6-4(1.2738) AISI : P+Ni Cutting Speed : 280 m/min. R.P.M : 70 rev./min. Feed : 22 mm/min. Feed per tooth : 0.2 mm/tooth Milling Method : Side Cutting Milling Depth : Axial : 3.0mm Radial : 0.2mm Coolant : Oil Mist Overhang : 70mm Machine : Machining Center 2 phone:+82--526-09, fax:+82--526-4373, www.yg1.kr, E-mail:yg1@yg1.kr 3 phone:+82--526-09, fax:+82--526-4373, www.yg1.kr, E-mail:yg1@yg1.kr
BALL INSERTS BALL HOLDERS - STEEL TAPER NECK For GENERAL For HARDENED RADIUS ( R ) HEIGHT ( H ) THICKNESS ( T ) (Ø) SHANK NECK (Ø) (Ø) () () TAPER ANGLE (θ ) Ø Ø Ø Ø Ø Ø XMBA080 XMBA XMBA0 XMBA0 XMBA0 XMBA0 XMBA0 XMBA3 For General Material (~HRc) For Hardened Material (HRc40~HRc65) XMB0C080 XMB0C XMB0C0 XMB0C0 XMB0C0 XMB0C0 XMB0C0 XMB0C3 R4.0 R5.0 R6.0 R8.0 R10.0 R.5 R.0 R.0 8 9.5 11 19.5 23.5 24.5 2.4 2.7 3.2 4.2 5.2 6.2 Ø Ø Ø Ø Ø,Ø ZBT08010 ZBT080 ZBT10 ZBT ZBT010 ZBT000 ZBT010 ZBT0 ZBT0 9 10.5 14.5 18 22.5 27 17 40 STRAIGHT NECK 65 75 1 145 170 195 4 43' 3 37' 2 51' 2 17' 3 23' 2 51' 3 26' 4 03' 1 38' TWFT07 TWFT08 TWFT TWBT TWBT TX08T07 TX10T08 TXT10 TX40T TXT TX60T BALL INSERT ADVANTAGES 1. Helical end gash ( "S" gash ) geometry. Low milling torque. Prevents Chattering. Improves Chip ejection. Prolong tool life. 2. Polished cutting edges. Better wear resistance and tool life. Improves repeatability in performance. Improves surface roughness on work-piece. Improves coating addition. 3. Special coating. Combine high hardness with high thermal stability against oxidation. Superior wear resistance. Faster feeds and speeds. The ball radius tolerance is ±0.01mm and the set-up accuracy is ±0.02mm SHANK NECK (Ø) (Ø) (Ø) () () Ø Ø Ø Ø Ø, Ø ZBS010 ZBS0 ZBS010 ZBS0 ZBS000 ZBS020 ZBS010 ZBS0 ZBS0 ZBS023 10.5 14.5 STEEL HOLDER ADVANTAGES 1. Premium alloy steel with excellent strength. 2. Precise shank tolerance (h6). 3. Black oxide treated, to prevent corrosion and improve lubricity. 18 22.5 27 65 40 75 45 95 1 145 1 170 140 195 TWFT TWBT TWBT TXT10 TX40T TXT TX60T 4 phone:+82--526-09, fax:+82--526-4373, www.yg1.kr, E-mail:yg1@yg1.kr 5 phone:+82--526-09, fax:+82--526-4373, www.yg1.kr, E-mail:yg1@yg1.kr
BALL HOLDERS - CARBIDE CORNER RADIUS INSERTS T D R H (Ø) SHANK (Ø) NECK (Ø) () () For GENERAL For HARDENED CORNER RADIUS ( R ) HEIGHT ( H ) THICKNESS ( T ) ZBC0801080 8 7.7 1 TWFT07 TX08T07 XMRA080 03 XMR0C080 03 R0.3 ZBC0 10 9.7 140 TWFT08 TX10T08 XMRA080 05 XMR0C080 05 8 2.4 Ø ZBC010 11.7 17 1 TXT10 XMRA080 10 XMR0C080 10 Ø ZBC010.7 0 TWFT TX40T XMRA 05 XMR0C 05 Ø ZBC000 19.7 60 0 TWBT TXT XMRA 10 XMR0C 10 9.5 2.7 Ø ZBC010 24.7 75 0 TWBT TX60T XMRA XMR0C Ø, Ø ZBC0 29.7 40 0 XMRA0 05 XMR0C0 05 Ø XMRA0 10 XMR0C0 10 11 3.2 XMRA0 XMR0C0 XMRA1 05 XMR0C1 05 Ø XMRA1 10 XMR0C1 10 11.2 3.2 XMRA1 XMR0C1 XMRA0 05 XMR0C0 05 Ø XMRA0 10 XMR0C0 10 4.2 XMRA0 XMR0C0 XMRA170 05 XMR0C170 05 Ø17 XMRA170 10 XMR0C170 10 4.2 XMRA170 XMR0C170 XMRA0 05 XMR0C0 05 Ø XMRA0 10 XMR0C0 10 5.2 XMRA0 XMR0C0 CARBIDE HOLDER ADVANTAGES 1. Equal tool rigidity with solid carbide end mill makes the stable and high finishing machining with the less vibration. 2. The high finishing machining for the deeper part of mold. Ø21 XMRA210 05 XMRA210 10 XMRA210 XMR0C210 05 XMR0C210 10 XMR0C210 * The other corner radius value are available on request. For General Material (~HRc) For Hardened Material (HRc40~HRc65) 5.2 3. The tool life is longer than steel holder. 4. Shrink Fit Holding system can be applied. 5. Upon request, the broken holder is able to be fixed. 6 phone:+82--526-09, fax:+82--526-4373, www.yg1.kr, E-mail:yg1@yg1.kr 7 phone:+82--526-09, fax:+82--526-4373, www.yg1.kr, E-mail:yg1@yg1.kr
CORNER RADIUS INSERTS CORNER RADIUS HOLDERS - STEEL TAPER NECK T D R H (Ø) SHANK NECK (Ø) (Ø) () () TAPER ANGLE (θ ) Ø Ø26 Ø Ø For GENERAL XMRA0 05 XMRA0 10 XMRA0 XMRA260 05 XMRA260 10 XMRA260 XMRA0 05 XMRA0 10 XMRA0 XMRA3 05 XMRA3 10 XMRA3 For HARDENED XMR0C0 05 XMR0C0 10 XMR0C0 XMR0C260 05 XMR0C260 10 XMR0C260 XMR0C0 05 XMR0C0 10 XMR0C0 XMR0C3 05 XMR0C3 10 XMR0C3 * The other corner radius value are available on request. For General Material (~HRc) For Hardened Material (HRc40~HRc65) CORNER RADIUS ( R ) HEIGHT ( H ) 19.5 19.5 23.5 23.5 CORNER RADIUS INSERT ADVANTAGES THICKNESS ( T ) 1. The optimum geometry of the tool to achieve the better reliability and less vibration and cutting load. 2. Interchangeability with i-xmill ball holder, but the precise cutting is possible with i-xmill corner radius holder due to higher stability and strength of tool. 3. The various and wide cutting range makes it possible to machine over the roughing and finishing. 4. Special coating makes high hardness with high thermal stability against oxidation. The corner radius tolerance is ±0.0mm and set-up accuracy is ±0.02mm 6.2 6.2 Ø, Ø Ø, Ø Ø, Ø17 Ø, Ø21 Ø, Ø26 Ø Ø ZRT08010 ZRT080 ZRT10 ZRT ZRT0 ZRS010 ZRS010 ZRS0 ZRS000 ZRS020 ZRS010 ZRS0 ZRS0 ZRS023 ZRS3 ZRS3 6.7 8.6 10.2 STRAIGHT NECK (Ø) SHANK (Ø) NECK (Ø) 11 19 24 29 31 STEEL HOLDER ADVANTAGES 1. Premium alloy steel with excellent strength. 2. Precise shank tolerance (h6). 3. Black oxide treated, to prevent corrosion and improve lubricity. 10 18 23 27 28 22 60 65 60 80 70 80 80 () 1 1 0 () 1 5 140 180 1 0 0 2 0 2 9 2 43' 4 45' 1 ' 2 ' TWFT07 TWFT08 TWFT TWBT TWBT TX08T07 TX10T08 TXT10 TXT10 TX40T TXT TX60T 8 phone:+82--526-09, fax:+82--526-4373, www.yg1.kr, E-mail:yg1@yg1.kr 9 phone:+82--526-09, fax:+82--526-4373, www.yg1.kr, E-mail:yg1@yg1.kr
ASSEMBLY OF Make sure to clean the insert and insert seat. Slide the insert into the slot of the holder. Tighten the screw using anti-seize compound. Ø, Ø Ø, Ø17 Ø, Ø21 Ø, Ø26 Ø, Ø CLAMPING TORQUE [ N m ] 1.0 1.5 2.5 3.5 5.0 6.0 6.5 *When the screw is worn out, please change the new screw. *Please tighten up the screw with recommended torque. (Please refer to the table) *Don't press down the insert, when the screw is tightened. WORK HARDNESS STRENGTH i-xmill Roughing~Finishing 8.0 10.0.0.0.0.0.0 BALL (XMBA, XMB0C Series) HB HRc N/mm 2 NON-ALLOYED STEELS CAST IRON ~280 ~ ~0 XMBA (XMB1A) 6370~7 ~11460 4240~80 3180~95 ~92 40~7640 1700~74 ~ 40~4580 1700~40 ~57 70~7380 10~7640 8~8910 ap HEAT RESISTANT STEELS 280~380 ~40 0~10 XMBA (XMB1A) 4770~11140 38~95 3180~9280 23~7560 1910~6680 ~6 70~5840 1910~4460 ~38 70~3710 11~4540 9~53 760~6 640~7000 3980~87 3180~8280 26~74 19~6960 ~6370 70~57 1060~5310 Recommend to reduce the feed rate to 70 ~ 85% when you use long tools. ae DIE TOOL STEELS PRE-HARDENED 380~480 40~ 10~10 XMBA (XMB1A) XMB0A (XMB1A) 11~ 9~3310 800~2970 800~4180 640~ 510~57 4~6370 ae : Roughing - 0.1 x D Finishing - Under Ø : 0.mm Ø~Ø17 : 0.mm From Ø : 0.40mm ap : Roughing - Under Ø : 0.0 x D From Ø : 0.05 x D Finishing - 0.1mm HARDENED STEELS 3180~70 ~6370 ~5840 ~5170 70~ 10~4580 8~4240 480~740 ~65 10~ XMB0A (XMB1A) 640~2860 510~ 4~23 480~3 380~4070 310~4580 0~ = rev./min. FEED = mm/min. CORNER RADIUS (XMRA, XMR0C Series) ae WORK HARDNESS STRENGTH i-xmill HB HRc N/mm 2 Roughing~Finishing 8.0 10.0.0,.0.0, 17.0.0, 21.0.0, 26.0.0,.0 NON-ALLOYED STEELS CAST IRON ~280 ~ ~0 XMRA (XMR1A) 6370~11940 ~95 4240~7960 3180~5970 ~4770 40~38 1700~3180 ~80 40~2860 1700~23 ~23 70~1910 10~ 8~70 HEAT RESISTANT STEELS 280~380 ~40 0~10 XMRA (XMR1A) 4770~11140 38~8910 3180~74 23~70 1910~4460 ~70 70~2970 1910~3340 ~2670 70~22 11~22 9~1780 760~14 640~11 DIE TOOL STEELS PRE-HARDENED 380~480 40~ 10~10 XMRA (XMR1A) XMR0A (XMR1A) 3980~11140 3180~8910 26~74 19~70 ~4460 70~70 1060~2970 9~40 800~1070 660~8 600~840 480~670 380~5 3~4 HARDENED STEELS 3180~87 ~7000 ~5840 ~4380 70~ 10~2800 8~23 480~740 ~65 10~ XMR0A (XMR1A) 640~880 510~700 4~580 4~5 380~4 310~340 0~280 = revolution per minute (rev/min) Vc = surface meter per minute (M/min) Dia. = diameter of insert (mm) Vf = feed speed (mm/min) f = feed per revolution (mm/rev) De = effective tool diameter (mm) ap = axial depth of cut (mm) Vc [M/min] = Vf [mm/min] = [rev/min] = De [mm] = () (π) (Dia.) 0 () (f) (Vc) (0) (π) (Dia.) 2 (ap) (Dia. - ap) ap Recommend to reduce the feed rate to 70 ~ 85% when you use long tools. ae ae : Roughing - 0.1 x D Finishing - 0.2mm ap : Roughing - Under Ø : 0.0 x D From Ø : 0.05 x D Finishing - Under Ø : 0.1mm From Ø : 0.2mm = rev./min. FEED = mm/min. ae = radial depth of cut (mm) 10 phone:+82--526-09, fax:+82--526-4373, www.yg1.kr, E-mail:yg1@yg1.kr 11 phone:+82--526-09, fax:+82--526-4373, www.yg1.kr, E-mail:yg1@yg1.kr