Page 1/7 MAY 2007 Revised ADKT 1505R8T-FF a Combination of and ISCAR is expanding the application range of the HELIMILL tools by a new 15 mm insert with a FEEDMILL configuration. The new ADKT 1505R8T-FF insert does not require any new tools. It can be clamped on any standard HELI2000 tool (.75-12.00 inch diameters) after modifying the corner radius on the tool to.08 inch. The HELI2000 cutters, when used with ADKT 1505R8T-FF inserts at small depths of cut (up to.06 inch), can run at extremely high table feeds. For example: at.06 DOC, a.06 feed per tooth can be applied. The tool life under the above-mentioned cutting parameters is remarkably high (see attached DOC vs. feed application range data). As with the other FEEDMILL tools, the resultant force exerted on the tool is directed axially towards the spindle. This feature enables using the tools also on small to medium machines, less rigidly clamped parts and yet to attain very high metal removal rates.
Page 3 / 7 ADKT 1505R8T-FF Inserts for Very High Feed Milling R.106 R.500 l Ref.390 ap max (2) ap (1) S Tool Type of Designation l ap (1) ap max (2) S Types Machining ADKT 1505R8T-FF.626.06.138.244 1-2 Medium (1) Depth range at which up to.06 IPT feed may be applied. (2) At the ap to ap max depth range, a regular HELI2000 ADKT 1506 insert feed recommendations should be applied. (3) The cutting diameter of the tool is.020 larger than the nominal diameter when using this insert. Rampdown angles of the tools can be applied using this insert. IC928 P Steel M Stainless Steel K Cast Iron N Aluminum S High Temp. Alloys H Hardened Steel 3 Tool corner should be modified to R.08 Feed Recommendations: D+.020 (3) fz (IPT) ap Light Medium Heavy.06.031.047.06 fz Standard Tool Tool with a Modified Corner Tool Types 1 HM90 E90AD 2 HM90 F90A
Page 4 / 7 Recommended Cutting Conditions for ADKT 1506T8-FF Inserts Material Non-Alloy Steel ST-37 Alloy Steels Mold Steels Tool & Die Steel Stainless Steel )Austenitic( Stainless Steel )Martenitic( Cast Iron Grey Nodular High Temp. Alloys Hardened Mold Steel Workpiece Materials (1) SAE/AISI (DIN) (3) SAE 1020 (DIN 1.0402) SAE 4340 (DIN 1.6582) P20 (DIN 1.2311) H13 (DIN 1.2344) AISI 304L (DIN 1.4306) AISI 316L (DIN 1.4304) AISI 420 (DIN 1.4021) GG25 (DIN 036025) GGG50 (DIN 0.705) Titanium Ti6Al4V Inconell 718 (DIN 1.6582) SAE 4340 (DIN 1.6582) Hardness 130-180 HB 24-30 30-36 200-220 HB Carbide Grade ) Cutter (2 Overhang ]inch[ Coolant D.O.C. Ap max [inch] Cutting Conditions W.O.C. (2) Ae max [inch] Vc ]SFM[ fz [IPT].039 -.059 330-560.031 -.059 0.7 * D.059 -.079 330-490.028 -.051.039 -.059.031 -.059 0.7 * D 330-490.059 -.079.02 -.039.039 -.059.024 -.047 0.7 * D 330-490.059 -.079.02 -.031.039 -.059 0.7 * D 330-490.024 -.043 200 HB.02 -.039 0.7 * D 260-330.012 -.028 140 HB.02 -.039 0.7 * D 260-330.012 -.024 200 HB.02 -.059 0.7 * D 260-390.012 -.028 250 HB.039 -.059 0.7 * D 490-720.039 -.059 200 HB.039 -.059 0.7 * D 330-520.039 -.059 35-45 IC928 2-3 * D Wet.039 0.7 * D 70-150.016 -.024 200 HB IC928 2-3 * D Wet.039 0.7 * D 70-100.008 35-45.02 -.039.016 -.031 0.7 * D 260-390.02.004 -.067 (1) Example of typical material. (2) As a reference for W.O.C. Ae=0.7*D D- cutter diameter (inch). (3) Same or equivalent grade.
Page 5 / 7 Machining Examples Sholder Milling Fz =.06 IPT Ap =.06 inch P = 13.4 HP Tool life = 25 min Metal removal rate = 15.3 in 3 /min Ap =.08 inch P = 13.4 HP Tool life = 40 min Metal removal rate = 14.2 in 3 /min Ap =.06 inch P = 11.4 HP Tool life = 60 min Metal removal rate = 10.2 in 3 /min Vc = 430 SFM Ap =.031 inch P = 6.7 HP Tool life = 120 min Metal removal rate = 4.15 in 3 /min Fz =.06 IPT P = 11.4 HP Tool life = 70 min Metal removal rate = 10.2 in 3 /min
Page 6 / 7 Pocket Milling + Rampdown Vc = 590 SFM Fz =.06 IPT B =.67 inch P = 11.3 HP Tool life = 40 min Metal removal rate = 8.36 in 3 /min Rampdown 3 Deg Workpiece: AISI 420 HB 160 Vc = 330 SFM B =.67 inch P = 6.7 HP Tool life = 60 min Metal removal rate = 3.05 in 3 /min Rampdown 3 Deg Workpiece: AISI 316L HB160 Vc = 330 SFM Fz =.024 IPT B =.67 inch P = 3.9 HP Tool life = 65 min Metal removal rate = 1.83 in 3 /min Rampdown 3 Deg
Page 7 / 7 Field Report During Operation After Machining Application Workpiece Material Milling cutter Spindle Square Shoulder + Slotting (see pictures) Armor plate (30-36 ), HM90 E90AD-D1.00-2-W1.00 BT40- Vertical Square Shoulder + Slotting (see pictures) Cutter Diameter [inch] 1.00 1.00 Z- Number of Teeth 2 2 Overhang [inch] 3.54 (3.6*D) 3.54 (3.6*D) Insert ADKT 1505R8T-FF ADKT 150524R-HM Carbide Grade IC928 IC950 Tool stability Good Good Coolant Type --- Emulsion Vc - Cutting Speed [SFM] 395 515 Spindle Speed [rpm] 1528 1970 fz Feed [IPT].019-.024.010 Vf Table Speed [IPM] 55.7-71 38.8 Ae Width of Cut [inch].59-1.00.59-1.00 Ap Depth of Cut [inch].040.02 Q metal removal rate [in 3 /min] Number of components per cutting edge 2.8.76 15 8 Time for one part [min] 7 12.5 Tool life per corner [min] 105 96