MFour (MW) How to mount an insert 1. Be sure to remove dust and chips from the insert mounting pocket. 2. Apply antiseize compound on portion of taper and thread of clamp screw. (1) Attach the screw (magnetic head) to the front end of the wrench. (2) While lightly pressing the insert against the pocket walls, put the screw into the hole of the insert and tighten. (Ref. to Fig. 1.) Tighten M3 screws (SB3065TRP) slightly inclined from the insert. (Ref. to Fig. 2.) surface of the insert. 0 3. When tightening the screw, make sure that the wrench is parallel to the screw. For recommended torque, Ref. to 7 4. After tightening the screw, make sure that there is no clearance between the insert seat surface and the pocket floor of the holder or between the insert side surfaces and the pocket walls of the holder. If there is any clearance, remove the insert and mount it again according to the above steps. Recommended Conditions MW1000MW1500 MW0625M0750 MW1500RMW3000R MW16MW18 MW20MW50 MW032RMW080R Carbon Steel 0.0020.0040.008 0.0030.0060.010 Chipbreaker GM SM GH Ramping, Helical milling and Vertical milling 1. Available for vertical milling. 2. NOT available for ramping and helical milling, because interference between workpiece and insert may occur. Recommended Insert Grades ( Speed:sfm) MGACOAT NANO PR1525 390600820 Alloy Steel 0.0020.0040.006 0.0030.0060.008 325530720 Mold Steel 0.0020.0030.005 0.0030.0050.008 260450600 Stainless Steel 0.0020.0030.005 0.0030.0050.006 325530650 Gray Cast Iron 0.0020.0040.007 0.0030.0070.010 Nodular Cast Iron 0.0020.0030.005 0.0030.0060.008 Titanium Alloys 0.0020.0030.005 0.0030.0060.008 Carbon Steel 0.0020.0040.007 0.0030.0060.008 390600820 Alloy Steel 0.0020.0030.005 0.0030.0050.007 325530720 Mold Steel 0.0020.0030.005 0.0030.0040.006 260450600 Stainless Steel 0.0020.0030.005 0.0030.0040.006 325530650 Titanium Alloys 0.0020.0030.005 0.0030.0050.007 Carbon Steel 0.0020.0040.008 0.0030.0080.012 390600820 Alloy Steel 0.0020.0040.006 0.0030.0080.010 325530720 Mold Steel 0.0020.0030.005 0.0030.0060.009 260450600 Stainless Steel 0.0020.0030.005 0.0030.0050.006 325500650 Gray Cast Iron 0.0020.0040.008 0.0030.0090.012 Nodular Cast Iron 0.0020.0030.006 0.0030.0070.010 Titanium Alloys 0.0020.0030.005 0.0030.0060.008 PR1510 390600820 325500650 100160225 100160225 390600820 325500650 100160225 * with coolant is recommended for titanium alloys. : 1st Recommendation : 2nd Recommendation Vertical milling Insert Applicable chipbreaker range (Shouldering) Max. Width of Cut (ae) LOMU10 LOMU15 0.197" (5mm) 0.276" (7mm) 8
Performance Shouldering ( width ae = ød/2) Slotting Shouldering ( width ae = ød/2) Slotting MW0625...10 MW0750...10 MW1000 15 MW1500 15 MW16 10 MW18 10 MW25 15 MW1000 10 MW1500 10 MW20 10 MW50 10 MW50 15 MW2000R 15 MW3000R 15 MW0750...2T MW1000...2T () MW20...2T MW25...2T () MW040R 15 MW080R 15 MW1500R...10 MW2500R...10 MW032R...10 MW063R...10 Case Studies Structural Steel 1018 Construction machine part Vc=820sfm ap ae=0.158 0.787in fz=0.006ipt(vf=53ipm) Wet MW32S32104T(4 flutes) LOMU100408RGM(PR1525) < Conditions> Vc=600 sfm GM Chipbreaker : S50C Length 1. ndmill: Same length as of the dimension 2. Face mill: H of the dimension + minimum overhang length of the arbor Structural Steel 1018 Machine parts Vc=820sfm ap ae=0.128 0.787in (Grooving) fz=0.008ipt (Vf=94ipm) DRY MW20S20103T(3 flutes) LOMU100408RGM(PR1525) 0 PR1525 Competitor A (Positive Cutter) Chip Removal=6.59in3/min. Chip Removal=4.39in3/min. MW showed stable milling without chattering at higher feed, improving the cutting efficiency by 150%. Burrs are prevented and excellent surface finish is achieved. (Customer valuation) PR1525 Competitor B (Positive Cutter) Chip Removal =8.79in3/min (Stable milling) Chip Removal = 6.97in3/min (Unstable) No chattering with MW, while Competitor B chattered at the same cutting conditions. No burrs with MW and excellent surface finish is gained.. (Customer valuation) Stainless Steel 155PH(42HRC) Hot Die Steel SKD61(45HRC) Aircraft Part Vc=590sfm ap ae=0.079 0.984in fz=0.004ipt (Vf=28ipm) Wet MW32S32104T(4 flutes) LOMU100408RGM(PR1525) 5.12in 0.98in Mold Part Vc=330sfm ap ae=0.138 1.181in fz=0.004ipt (Vf=15ipm) DRY MW32S32104T(4 flutes) LOMU100408RGH(PR1525) PR1525 Competitor C (Positive Cutter) Chip Removal = 2.18in3/min (Further Milling Possible) Chip Removal = 1.64in3/min (Unable to continue cutting) No chattering and more stable milling is possible with MW. Despite the milling difficulty because of the properties of the material, PR1525 kept good cutting edge form, minimizing wear and adhesion. (Customer valuation) PR1525 Competitor D (Positive Cutter) Chip Removal = 2.56in3/min (Further Milling Possible) Chip Removal = 1.28in3/min (Unable to continue cutting) MW doubled cutting efficiency. Furthermore, MW inserts have double number of edges (4edge), which enables a drastic cost reduction. (Customer valuation) 9
Advantage 3 Shouldering Slotting Superior Fracture Resistance due to Thick dge Design Facing Vertical dge Thickness: 8.55mm Stable Clamping due to the Unique Insert Face Design 5mm 8.5mm Fracture Resistance Comparison Condition : SCM440H (3842HS) Vc=328sfm apxae =.080 x 4.000 Interruption with a slot on the workpiece fz =.008.018ipt DRY GM Chipbreaker GH Chipbreaker Feed Rate (ipt) 0.008 0.010 0.012 0.014 0.016 0.018 Advantage 4 Neutral Inserts Available for Shouldering and Facing Wide Application Range 0 Neutral Insert are applicable to lefthand cutters (custom order). Side edge Advantage 5 Base dge xtended Tool Life by New MGACOAT NANO Technology PR1525 for steel and stainless steel PR1510 for cast iron Prevents wear and fracture with high hardness (35GPa) and superior oxidation resistance (oxidation temperature: (1,150 C) Advantage 6 4 Chipbreakers for Various Applications Max ap 0.315in Smooth Chip vacuation Surface Finish Oriented Properly curled chips 11
MSix (MFWN) Precautions for use (How to mount the insert) 1. Be sure to remove dust and chips from the insert mounting pocket. 2. After applying antiseize compound on portion of taper and thread, attach the screw to the front end of the wrench. While lightly pressing the insert against the pocket walls, put the screw into the hole of the insert and tighten. (Ref. to Fig. 1) 3. When tightening the screw, make sure that the wrench is parallel to the screw. Remember that the screw hole of the holder for xtra fine pitch is inclined to the pocket floor. (Ref. to Fig. 2 and Fig. 3) 4. Be careful not to tighten the screw with excessive torque. Recommended torque is 4.2N m for M5 screw (SB50140TR) and 3.5N m for M4 screw (SB40140TRN). 5. After tightening the screw, make sure that there is no clearance between the insert seat surface and the pocket floor of the holder or between the insert side surfaces and the pocket walls of the holder. If there is any clearance, remove the insert and mount it again according to the above steps. 6. To change the cutting edge of the insert, turn the insert counterclockwise. (Ref. to Fig. 4) The insert corner identification number is stamped on the top surface of the insert. 0 Recommended Conditions Insert Grades Speed Vc (sfm) Carbon Steel PR1525 400600800 Alloy Steel PR1525 320520720 Mold Steel PR1525 260450600 Stainless Steel PR1525 320500650 Gray Cast Iron PR1510 390600820 Nodular Cast Iron PR1510 325500650 Titanium Alloys PR1510 100160225 Chipbreaker 0.002 0.004 0.008 0.012 0.016 GM 0.004 0.008 0.012 SM 0.002 0.005 0.008 GH 0.008 0.012 0.016 GL 0.002 0.005 0.008 GM 0.004 0.008 0.012 SM 0.002 0.005 0.008 GH 0.008 0.012 0.016 GL 0.002 0.005 0.008 GM 0.004 0.006 0.010 SM 0.002 0.003 GH 0.006 0.008 0.012 GL 0.002 0.003 0.006 GM 0.004 0.006 0.010 SM 0.002 0.005 0.008 GL 0.002 0.005 0.008 GM 0.004 0.008 0.012 SM 0.002 0.005 0.008 GH 0.008 0.012 0.016 GL 0.002 0.005 0.008 GM 0.004 0.006 0.010 SM 0.002 0.003 0.006 GH 0.006 0.008 0.012 GL 0.002 0.003 0.006 SM 0.002 0.003 0.006 GL 0.002 0.003 0.006 Vertical milling Coarse pitch (with shim) Fine pitch (without shim) Cutter (For GH Chipbreaker, fz=0.0118ipt is Specification recommended.) xtra fine pitch (without shim) (The use of the GH breaker is not recommended.) * The boldfaced number indicates a center value of recommended condition. : 1st Recommendation : 2nd Recommendation All items Max. Width of Cut (ae) 0.315in (8mm) 16
Recommended Conditions (MC ndmill / Face Mill) JT Chipbreaker MC0500MC0750 MC10MC19 Recommended Insert Grades ( Speed: sfm) Holder Cermet MGACOAT PVD Coated Carbide MC1000MC1500 MC20MC40 MC1500RMC4000R MC040RMC160R Stainless Steel 0.0020.0030.004 0.0030.0050.006 Carbon Steel 0.0020.0040.006 0.0030.0060.010 Alloy Steel 0.0020.0040.005 0.0030.0060.008 Mold Steel 0.0020.0030.004 0.0030.0050.008 TN100M PR1225 PR1210 PR830 PR905 400525656 325560600 250400492 325525656 400600820 325525725 250560600 Gray Cast Iron 0.0020.0040.006 0.0030.0070.010 Nodular Cast Iron 0.0020.0030.004 0.0030.0060.008 Titanium Alloys 0.0020.0030.004 0.0030.0060.008 400600820 325492656 98164225 325560600 400525656 325560600 250400492 325560600 250400525 75115164 * with coolant is recommended for Titanium Alloy. : 1st Recommendation : 2nd Recommendation JS Chipbreaker MC0500MC0750 MC10MC19 Insert Grades ( Speed: sfm) Holder MGACOAT PVD Coated Carbide MC1000MC1500 MC20MC40 MC1500RMC4000R MC040RMC160R Stainless Steel 0.0020.0030.004 0.0030.0040.005 400600820 Carbon Steel 0.0020.0040.005 0.0030.0060.007 400600820 Alloy Steel 0.0020.0030.004 0.0030.0050.006 325525725 Mold Steel 0.0020.0030.004 0.0030.0040.005 250450600 PR1225 PR830 PR1025 325450600 400525656 325450600 250400500 325450600 325400500 : 1st Recommendation : 2nd Recommendation 0 JA Chipbreaker Insert Grades ( Speed: sfm) Carbide GW25 Aluminium Alloys (Si 13% or below) 0.0020.012 6562625 Aluminium Alloys (Si 13% or above) 0.0020.008 656984 PCD Insert Grades ( Speed: sfm) PCD KPD230 (KPD001) Aluminium Alloys (Si 13% or bellow) 0.0020.012 16404921 Aluminium Alloys (Si 13% or above) 0.0020.006 9843280 Please observe below precautions fully. Failure to observe the precautions may cause serious damage Warning to human body. Warning about Max. Revolution indicated on main body 1. When running the endmill and the face mill at revolutions exceeding the maximum revolution limit, the inserts or toolholder may be damaged due to the centrifugal force. 2. For actual practical revolution, please set within recommended cutting condition. 3. When using at a higher revolution (over 10,000min 1 ), refer to the table to adjust the balance of MC and suitable arbor. Max. Revolution (min 1 ) Balance quality grade G ISO 19401 / 8821 (JIS B0905) 20,000 G16 30,000 G6.3 30,000 G2.5 27
MC Features of MC Perfect 90 Shoulders < Surface Comparison> Performance of MC ndmill (1) Length When Using BDMT 11mmtype Insert (Standard / Straight Shank) (mm / in) Length A (in) ø8mm MC10S1011 0.670 ø12mm MC0500... MC12S1611 ø16mm MC0625S62511T ø0.625in MC16S1611T ø0.750in MC0750S75011T ø20mm MC20S2011T ø1.000in MC1000S10011T ø25mm MC25S2511T ø1.250in MC1250S12511T ø32mm MC32S3211T 0.787 1.180 1.180 1.790 1.180 1.790 1.260 1.890 1.580 2.360 Low cutting force (Internal evaluation) Shouldering ( width ae = ød/2) (JT chipbreaker Vc=400 SFM :1049) Slotting Ramping and Helical Milling < Force Comparison> MC10S1011 0 MC0500... MC12S1611 Tool diameter ø0.787in 1049 Vc=328sfm Shouldering ap ae=0.354 0.3936in fz=0.008ipt Dry (In house evaluation) (Internal evaluation) MC0625S62511T MC16S1611T Chipbreaker JT Chipbreaker (General Purpose) JA Chipbreaker (For Aluminum) MC0750S75011T MC20S2011T Low cutting force JS chipbreaker MC1000S10011T MC25S2511T force 20% lower MC1250S12511T MC32S3211T 28
(2) Length When Using BDMT 11mmtype Insert () Length A (in) (3) Length When Using BDMT 17mmtype Insert Length A (in) ø0.750in MC20S2014011T ø20mm MC0750S7505.211T 2.362 3.543 ø1.000in ø25mm MC1000S10017 MC25S2517 1.417 2.126 ø1.000in MC25S2516011T ø25mm MC1000S1006.311T ø1.250in MC32S3220011T ø32mm MC1250S1257.911T ø1.500in MC40S3224011T ø40mm MC1500S1259.511T 2.362 3.957 3.957 5.118 3.957 5.119 ø1.250in ø32mm ø1.500in ø40mm MC1250S12517 MC32S3217 MC1500S12517 MC40S3217 ø1.000in MC1000S1006.317 ø25mm MC25S2516017 ø1.250in MC1250S1257.917 ø32mm MC32S3220017 ø1.500in MC1500S1259.517 ø40mm MC40S3224017 1.575 2.362 1.969 2.953 2.362 3.937 3.937 5.118 3.937 5.118 (JT chipbreaker Vc=400 SFM :1049) (JT chipbreaker Vc=400 SFM :1049) Shouldering ( width ae = ød/2) Slotting Ramping and Helical Milling Shouldering ( width ae = ød/2) Slotting Ramping and Helical Milling MC0750S7505.211T MC20S2014011T MC1000S10017 MC250S2517 0 MC1000S1006.311T MC25S2516011T MC1250S12517 MC32S3217 MC1250S1257.911T MC32S3220011T MC1500S12517 MC40S3217 MC1500S1259.511T MC40S3224011T MC1000S1006.317 MC25S2516017 MC1250S1257.917 MC32S3220017 MC1500S1259.517 MC40S3224017 29
MC Performance of MC Milling Cutter Length When Using BDMT 11mmtype Insert Length A (in) Shouldering ( width ae = ød/2) (JT chipbreaker Vc=400 SFM :1049) Slotting ø40mm ø1.500in ø50mm ø2.000in ø63mm ø2.500in ø80mm ø3.000in ø100mm ø4.000in ø125 ø160 MC1500R11T5T MC040R115TM 4.528 MC2000R11T5T MC050R11OTM 3.937 MC2500R11T6T MC063R11OT(M) 3.740 MC063R11OTM MC3000R11T7T MC080R11OT(M) 3.740 MC4000R119TN MC100R119TN MC125R1111T(M) 4.252 MC160R1114T(M) MC1500R11T5T MC040R115TM MC2000RTT MC4000RTT MC050R11TM MC100R119TN MC100R119TMN MC125R1111T(M) MC160R1114T(M) 0 Length When Using BDMT 17mmtype Insert Length A (mm) Shouldering ( width ae = ød/2) (JT chipbreaker Vc=400 SFM :1049) Slotting ø40mm MC040R174TM 4.528 ø50mm MC2000R174T ø2.000in MC050R17OTM 3.937 MC2500R174T ø63mm MC063R17OT 3.740 ø2.500in MC3000R176T MC063R17OTM ø80mm MC4000R177T ø3.000in MC080R17OT 3.740 ø100mm MC040R174TM ø125mm MC125R179T(M) 4.252 ø4.000in MC100R17OTN ø160mm MC160R1712T(M) MC2000R174T MC050R17TM MC2500R17T MC4000R17TN MC063R17T(M) MC100R17TN MC100R177TMN MC125R179T(M) MC160R1712T(M) 30
Ramping, Helical milling and Vertical milling 0 31
MCX Recommended Conditions JS Chipbreaker JT Chipbreaker Stainless Steel 0.00120.00160.0020 0.00200.00240.0028 Carbon Steel 0.00160.00310.0039 0.00240.00390.0047 Alloy Steel 0.00160.00240.0031 0.00240.00310.0039 Mold Steel 0.00160.00240.0031 0.00240.00310.0039 Recommended Insert Grades ( Speed Vc: sfm) MGACOAT PVD Coated Carbide PR1225 PR1210 PR830 PR1025 PR905 400600820 400600820 325525725 250450600 Gray Cast Iron 0.00160.00310.0039 0.00310.00390.0059 Nodular Cast Iron 0.00160.00240.0031 0.00310.00390.0047 Titanium Alloys 0.00160.00240.0031 0.00310.00390.0047 400600820 325500656 98164225 400500600 325450600 250400500 325525656 325450600 250400525 75115164 * with coolant is recommended for titanium alloys. : 1st Recommendation : 2nd Recommendation Slant Milling / Helical Milling For the plunge depth per revolution when helical milling, refer to the cutting performance data for each tool. Use compressed air during machining. 0 Max.Ramping Applicable Insert (in) Angle ( ) ø.315 Not Recommended ø.400 1.5 ø.472,ø.551 2 ø.630 3 ø.669,ø.709 1.5 ø.787 BDMT0703 2 ø.827 1.8 ø1.00 1.3 ø1.02 1.2 ø1.26 0.8 ø1.30 0.5 34
Performance of MCX ndmill (JT chipbreaker Vc=400 SFM :1049) Length A (in) Shouldering ( width ae = ød/2) Slotting Ramping and Helical Milling ø8mm MCX08S10071T 0.630 ø0.375in ø10mm MCX0375S375071T MCX10S10071T 0.670 ø0.500in ø12mm MCX0500S500072T MCX12S12072T 0.709 1.18 ø0.625in ø16mm MCX0625S625074T MCX16S16073T 0.787 1.57 ø0.750in ø20mm MCX0750S750074T MCX20S20074T 0.787 1.57 ø1.000in ø25mm MCX1000S100075T MCX25S25075T 1.000 1.97 ø1.250in ø32mm MCX1250S125076T MCX32S32076T 1.180 1.97 MCX08S10071T MCX0375S375071T MCX10S10071T MCX0500S500072T MCX12S12072T * Machining with extended overhang length is not recommended for ø0.315in and ø0.394in. * The cutting performance list shows applicable range of JT Chipbreaker (PR830) with Standard flutenumber type. For Multidge type, use with 70% or less of ap. * conditions of JS Chipbreaker (1) For MCX0375MCX0500 / MCX08MCX12 Decrease the feed rate by 25% according to cutting capability list. (2) For MCX 0625 / MCX16 and over Decrease the feed rate and ap by 30% according to cutting capability list. MCX0625S625074T MCX16S16073T MCX0750S750074T MCX20S20074T MCX1000S100075T MCX25S25075T MCX1250S125076T MCX32S32076T 0 Performance of MCX Face Mill ø1.250in ø32mm ø1.500in ø40mm ø2.000in ø50mm ø2.500in ø63mm MCX1250R078T MCX032R078TM MCX1500R0710T MCX040R0710TM MCX2000R0712T MCX050R0712TM MCX2500R0714T MCX063R0714TM Length A (in) 3.937 MCX032R078TM MCX040R0710TM (JT chipbreaker Vc=400 SFM :1049) Shouldering ( width ae = ød/2) MCX050R0712TM MCX063R0714TM * Not Recommended for Slotting. 35
Recommended Conditions (When using a notched insert) Recommended Insert Grades ( Speed: sfm) MGACOAT PVD Coated Carbide PR1225 PR1230 PR1210 PR830 PR905 Carbon Steel 0.0030.0040.006 400600875 400600725 325450600 Alloy Steel 0.0030.0040.006 325525725 325525650 325450600 Mold Steel 0.0030.0040.006 250450600 250450525 325400500 Gray Cast Iron 0.0030.0060.007 400600875 325450600 Nodular Cast Iron 0.0030.0060.007 325500725 325400500 Titanium Alloys 0.0030.0040.006 325175225 75125175 * with coolant is recommended for titanium alloy. : 1st Recommendation : 2nd Recommendation 1. The recommended cutting conditions above are for notched inserts. 2. If using an insert without notch, the cutting depth (ap) and width (ae) should be less than 60% of those of a notched insert. JA Chipbreaker Recommended Insert Grades ( Speed Vc : sfm) Carbide GW25 0 Aluminum Alloy (Si 13% or less) Aluminum Alloy (Si 13% or less) 0.0020.012 6562625 0.0020.008 656984 When using inserts with cornerr(r)1.6 or larger, additional modifications of the cutter body will be necessary. Ref. to the table below for the recommended modifications. (Additional grind off is not necessary when cornerr is 1.2mm or less.) Additional Processing Dimension Insert CornerR(r) to Body Corner 1.6 2.0 R1.0 2.4 R1.2 3.1 R1.6 4.0 R2.5 * Roundshaped additional processing is recommended. When applying chamfer shaped additional processing, do not cut away too much. 45
MCH 0 Performance (Used Machine: Machining center equivalent to AC15 / 18.5kW) MCH ndmill Type ø1.00in ø25mm ø1.25in ø32mm ø1.50in ø40mm ø2.00in ø50mm ø1.50in ø40mm ø2.00in ø50mm MCH1000W10001142T MCH025S251142T MCH1250W12501152T MCH032S321152T MCH1250W12501154T MCH032S321154T MCH1500W12501164T MCH040S321164T MCH1500W15001164T MCH040S421164T MCH2000W15001174T MCH050S421174T MCH2000W15001176T MCH050S421176T MCH1500W12501742T MCH040S321742T MCH1500W15001742T MCH040S421742T MCH2000W15001754T MCH050S421754T Length A (in) 1.89 2.24 2.56 2.99 2.91 3.50 2 Flute Type ( :1049) MCH1000W10001142T MCH025S251142T MCH1250W12501152T MCH032S321152T MCH1500W12501742T MCH1500W15001742T MCH040S321742T MCH040S421742T Shouldering Speed: Vc=325590sfm Feed: fz=0.0030.006 ipt Slotting speed: Vc=325400sfm Feed: fz=0.0030.005 ipt 4 Flute / 6 Flute Type MCH1250W12501154T MCH032S321154T MCH1500W12501164T MCH1500W15001164T MCH040S321164T MCH040S421164T MCH1200W15001174T MCH050S421174T MCH1200W15001176T MCH050S421176T MCH1200W15001754T MCH050S421754T 46 4 Flute / 6 Flute Type are not recommended for Slotting.
MCH Shell Mill Type ( : 1049) Length A (in) Shouldering ø1.58in ø40mm ø2.00in ø50mm ø2.48in ø63mm ø3.15in ø80mm ø3.94in ø100mm MCH040R1144TM 4.92 MCH2000R1156T MCH050R1156TM MCH2000R1724T MCH050R1724TM MCH2000R1744T MCH050R1744TM 4.84 4.41 5.43 MCH063R1734TO 4.53 MCH080R1746TO 5.12 MCH100R1746TO 5.12 MCH040R 1144TM MCH2000R 1156T MCH050R 1156TM D.O.C. (in) 1.57 1.18 0.79 0.40 0 speed: Vc=325600sfm Feed: fz=0.0030.006ipt 0.40 0.79 1.18 Width of Cut ae(in) MCH063R 1734TO MCH080R 1746TO MCH2000R 1724T MCH050R 1724TM MCH100R 1746TO MCH2000R 1744T MCH050R 1744TM Slotting is not recommended. 0 MCHBT50 (Integral Arbor type) MCHBT50SA (Replaceable Head type / Integral Arbor type) ( : 1049) Length L (in) Shouldering ø50mm MCH050R1184TBT50 MCH050R114TBT50SA MCH050R1774TBT50 143 speed: Vc=325600sfm Feed: fz=0.0030.006ipt ø63mm ø80mm ø100mm MCH063R1774TBT50 MCH063R174TBT50SA MCH080R1774TBT50 MCH080R174TBT50SA MCH100R1776TBT50 MCH100R176TBT50SA 173 MCH050R11 84TBT50 MCH050R11 4TBT50SA MCH080R17 74TBT50 MCH080R17 4TBT50SA MCH050R17 74TBT50 MCH100R17 76TBT50 MCH100R17 6TBT50SA Slotting is not recommended. MCH063R17 74TBT50 MCH063R17 4TBT50SA 47
MSR Heavy Milling Cutter Recommended Conditions Recommended Insert Grades ( Speed: sfm) Low Force General Purpose MGACOAT PVD Coated Carbide NB3P+NB4P NB3+NB4 PR1230 PR1210 PR660 PR830 PR905 Cast Iron 0.006 0.008 325500650 325450600 Carbon Steel 0.006 0.008 325500650 325450600 325500600 Stainless Steel Not recommended Aluminum / Copper Not recommended * For MSR, cutting speed should be carefully adjusted depending on the length of toolholder protruding from the end of machine spindle. : 1st Recommendation When the protruding length of toolholder is small, set the cutting speed to slightly higher than the recommended cutting conditions. : 2nd Recommendation When the protruding length of toolholder is large, set the cutting speed to slightly lower than the recommended cutting conditions. Conditions 1) Shouldering When using MSR100R1 Length A (in) Cast Iron Carbon Steel speed Conditions ap ae (in) Chip Removal Rate (in3/min) Less than 3.94in Vc=590sfm fz=0.008ipt 0.79 3.15 67.13 3.947.87in Vc=590sfm fz=0.008ipt 0.79 1.57 33.56 7.91in and over Vc=400sfm fz=0.008ipt 0.79 1.18 16.84 Less than 3.94in Vc=500sfm fz=0.008ipt 0.79 3.15 56.14 3.947.87in Vc=500sfm fz=0.008ipt 0.79 1.57 28.07 7.91in and over Vc=325sfm fz=0.008ipt 0.79 1.18 13.91 fz Length A (in) 0 When using MSR100R2 Cast Iron Carbon Steel Length A (in) speed Conditions ap ae (in) Chip Removal Rate (in3/min) Less than 5.12in Vc=590sfm fz=0.008ipt 1.57 1.57 67.13 5.129.06in Vc=590sfm fz=0.008ipt 1.57 0.79 33.56 9.09in and over Vc=400sfm fz=0.008ipt 1.57 0.79 22.46 Less than 5.12in Vc=500sfm fz=0.008ipt 1.57 1.57 56.14 5.129.06in Vc=500sfm fz=0.008ipt 1.57 0.79 28.07 9.09in and over Vc=325sfm fz=0.008ipt 1.57 0.79 18.55 fz 4 4 4 4 3 3 A When using MSR100R4 Cast Iron Carbon Steel 11.06in and over Vc=325sfm fz=0.008ipt 2.95 0.39 17.39 2) Slotting When using MSR100R1 Cast Iron Carbon Steel Length A (in) Length A (in) speed speed Conditions Conditions fz fz ap ae (in) ap ae (in) Chip Removal Rate (in3/min) Less than 7.09 in Vc=590sfm fz=0.008ipt 2.95 0.79 63.16 7.0911.02in Vc=590sfm fz=0.008ipt 2.95 0.39 31.61 11.06in and over Vc=400sfm fz=0.008ipt 2.95 0.39 21.05 Less than 7.09 in Vc=500sfm fz=0.008ipt 2.95 0.79 52.66 7.0911.02in Vc=500sfm fz=0.008ipt 2.95 0.39 26.30 Chip Removal Rate (in3/min) Less than 3.94in Vc=590sfm fz=0.008ipt 0.55 3.94 58.95 3.947.87in Vc=500sfm fz=0.008ipt 0.28 3.94 24.59 7.91in and over Vc=400sfm fz=0.008ipt 0.16 3.94 11.23 Less than 3.94in Vc=500sfm fz=0.008ipt 0.28 3.94 24.59 3.947.87in Vc=400sfm fz=0.008ipt 0.16 3.94 11.23 7.91in and over Vc=325sfm fz=0.008ipt 0.12 3.94 6.96 60 60 When using MSR100R2 Cast Iron Carbon Steel Length A (in) *Slotting is not recommended for 4 stage cutters speed Conditions fz ap ae (in) Chip Removal Rate (in3/min) Less than 5.12in Vc=590sfm fz=0.008ipt 0.55 3.94 58.95 5.129.06in Vc=500sfm fz=0.008ipt 0.28 3.94 24.59 9.09in and over Vc=400sfm fz=0.008ipt 0.16 3.94 11.23 Less than 5.12in Vc=500sfm fz=0.008ipt 0.28 3.94 24.59 5.129.06in Vc=400sfm fz=0.008ipt 0.16 3.94 11.23 9.09in and over Vc=325sfm fz=0.008ipt 0.12 3.94 6.96
2) Slotting When using MSR160R1 Cast Iron Carbon Steel Length A (in) Conditions speed fz Q&A ap ae (in) Chip Removal Rate (in 3 /min) Less than 3.94in Vc=600sfm fz=0.008ipt 0.39 6.30 56.63 3.947.87in Vc=500sfm fz=0.008ipt 0.20 6.30 28.32 7.91in and over Vc=400sfm fz=0.008ipt 0.16 6.30 14.83 Less than 3.94in Vc=500sfm fz=0.008ipt 0.20 6.30 23.43 3.94in7.87in Vc=400sfm fz=0.008ipt 0.12 6.30 14.04 7.91in and over Vc=325sfm fz=0.008ipt 0.08 6.30 6.22 When using MSR160R2 Length Conditions Chip Removal Rate ap ae (in) A (in) speed fz (in 3 /min) Less than 5.12in Vc=600sfm fz=0.008ipt 0.39 6.30 56.63 Cast Iron 5.129.06in Vc=500sfm fz=0.008ipt 0.20 6.30 23.43 9.09in and over Vc=400sfm fz=0.008ipt 0.16 6.30 14.83 Less than 5.12in Vc=500sfm fz=0.008ipt 0.20 6.30 23.43 Carbon Steel 5.129.06in Vc=400sfm fz=0.008ipt 0.12 6.30 11.11 9.09in and over Vc=325sfm fz=0.008ipt 0.08 6.30 6.22 *Slotting is not recommended for 4 stage cutters Q1 A1 Q2 A2 Q3 A3 What cutting conditions are recommended in most cases for MSR? Vc=500sfm, fz=0.008ipt, larger cutting depth and smaller cutting width What is the required equipment for MSR? In case of MSR100R2 e.g.) Load meter 120% e.g.) Load meter 90% 1st Pass 2nd Pass 3rd Pass ap ae: 0.59 2.95in Maximum spindle revolution should be lower than 4000RPM. BT50 or larger. * The reason it is not recommended for high RPM spindle machines is due to their lower torque value. * Although MSR works with BT40 shank, maximum available fz is about 0.004ipt. What are the points to remember when using a lower horsepower machine? 3rd Pass 2nd Pass 1st Pass ap ae: 1.77 0.98 Do not use large size cutters. Ø2.5" or Ø3.0" are recommended Please increase cutting speed and decrease feed rate. Set up conditions to get the largest available torque by checking torque curve of the machine. In conditions of Vc=500sfm, insufficient torque was amiable due to being in high gear. In this case, use Vc which can exert enough torque, such as Vc=400sfm. * Machine torque curve is a priority. 0 Q4 How do I deal with an unstable workpiece? Decrease feed rate during the ffective combinations for maintaining cycle time while A4 initial cut. Q5 What tool life can I expect? * Vibration and workpiece movement are most likely to occur upon the cutters initial entry entry into the cut. reducing the feedrate. Vc=500sfm, fz=0.008ipt Vc=650sfm, fz=0.006ipt A5 xample: Chip weight: 700kg/Corner (Result by PR660) time: 90min. (calculated value) distance: 65m (calculated value) Metal Removal Rate? About 7.8kg chips removed per minute Tool life time = 700kg (Chip weight) 7.8kg (Chip evacuation amount per 1min)=90min distance= 90min (Time by the end of tool life) x 717mm/min (Table feed ratio per 1min)=65m * Vc=150m/min, apxae: 20x70mm, Vf=717mm/min. * Tool: MSR100R2 (6 Flutes) Q6 How do I reduce chattering? If chattering occurs, then the following conditions are recommended. A6 Reduce cutting speed and increase feed rate. In case of Steel Vc=250sfm fz=0.010ipt In case of Cast Iron Vc=250sfm fz=0.014ipt 61 61