AXD TOOLS NEWS. Multi functional milling cutter for high speed & performance machining of aluminum and titanium alloys. B116E

Transcription

1 TOOLS NEWS For Machining of Aluminium and Titanium Alloys AXD Update B116E Multi functional milling cutter for high speed & performance machining of aluminum and titanium alloys.

2 For Machining of Aluminium and Titanium Alloys AXD7000 for excellent ramping and overall performance. Multi Functional Milling AXD AXD Ramping Slotting 3D copying Shoulder milling Pocketing AXD can be effectively used for pocket machining without the need for a prepared hole. Helical milling Face milling Extremely Stable Under High Centrifugal Forces At high spindle speeds the double clamping screws prevent insert displacement caused by centrifugal force. The double clamping offers both reliability and safety. <Cutting conditions> Tools : AXD A04RA AXD A03RA : XDGX175008PDFR-GL XDGX227008PDFR-GL Revolution : min -1 Displacement due to Centrifugal Force displacement (!m) Competitor A Competitor B AXD4000 displacement (!m) AXD7000 Competitor A Competitor B 5 mm Measurement area High Spindle Speeds Safe and reliable high spindle speed milling can be achieved due to the use of the double screw clamping and Mitsubishi Material s proprietary Anti Fly mechanism (Double AFI). Balance Quality Double AFI mechanism The holder is balanced to G6.3 or better at 10000min -1, according to the ISO1940 standard. (The holder is balanced without the inserts and the screws in place) 1

3 Grade Features DLC coated LC15TF MP9120 Accumulating Al-Ti-Cr-N coating PVD coatings have properties such as toughness, low coefficient of friction and excellent welding, wear and heat resistance. This results in tough, precision grades such as MP9120. Excellent welding resistance due to low coefficient of friction TOUGH-Σ A fusion of the separate coating technologies; PVD and multi-layering, realises extra toughness. PVD accumulated coating Special cemented carbide substrate Multi-layering of the coating prevents any cracks penetrating through to the substrate. Heat resistance Oxidation temperature (Cº) Conventional MP Hardness (Hv) Wear resistance Grhical representation. Coefficient of friction Work Material Grade Ti-6Al-4V Measured at 600 C S Titanium Alloy, Heat Resistant Alloy Conventional MP AXD4000 GL AXD4000 / AXD7000 Improved fracture resistance compared to GL breaker Low cutting resistance breaker emphasises the good sharpness AXD4000 and AXD7000 recommendation Depth of cut AXD4000 AXD7000 Low Machine Power High 2

4 For Machining of Aluminium and Titanium Alloys MULTI FUNCTIONAL MILLING For Aluminium and Titanium Alloys Finishing Roughing AXD4000 Fig.1 ød1 ød4 Fig.2 L2 ød1 ød4 L2 y SHANK TYPE Type A Type B Type Corner Radius Order Number Stock Teeth Dimensions (Note 1) The maximum allowable revolutions are set to ensure tool and insert stability. (Note 2) When using the tool at high spindle speeds, ensure that the tool and chuck are correctly balanced. (Note 3) Note for inserts with a corner radius of 1.6 and above, as corner radius increases the and L2 dimensions decreases. Clamp Torque (N m) : TS3SBS=1.5, TS3SB=1.5 Max.Depth of Cut Max. Allowable Revolution Re R D1 L2 D4 (min -1 ) Clamp Screw Wrench Anti-seize Lubricant AXD4000R201SA20SA a TS3SBS TKY08D MK1KS 252SA25SA a TS3SB TKY08D MK1KS 252SA25LA a TS3SB TKY08D MK1KS 282SA25SA a TS3SB TKY08D MK1KS SA25ELA a TS3SB TKY08D MK1KS 322SA32SA a TS3SB TKY08D MK1KS SA32LA a TS3SB TKY08D MK1KS 352SA32SA a TS3SB TKY08D MK1KS 352SA32ELA s TS3SB TKY08D MK1KS 403SA32SA a TS3SB TKY08D MK1KS 403SA42SA a TS3SB TKY08D MK1KS 403SA32ELA s TS3SB TKY08D MK1KS AXD4000R201SA20SB a TS3SBS TKY08D MK1KS 252SA25SB a TS3SB TKY08D MK1KS 252SA25LB a TS3SB TKY08D MK1KS 282SA25SB s TS3SB TKY08D MK1KS SA25ELB a TS3SB TKY08D MK1KS 322SA32SB a TS3SB TKY08D MK1KS SA32LB a TS3SB TKY08D MK1KS 352SA32SB s TS3SB TKY08D MK1KS 352SA32ELB a TS3SB TKY08D MK1KS 403SA32SB a TS3SB TKY08D MK1KS 403SA42SB a TS3SB TKY08D MK1KS 403SA32ELB s TS3SB TKY08D MK1KS Type(Fig.) Right hand tool holder only. XDGX1750pp PDpR-pp 3 a : Inventory maintained in Jan.

5 Fig. 1 ød12 Fig. 2 ød12 Fig. 3 ød9 ød9 ø40 W1 ø50 W1 ø125 ø63 ø80 ø100 L8 L7 L7 L8 L7 L8 ød12 ød9 W1 ød8 ød11 ød8 ød11 ød8 ød1 ød1 ød1 Right hand tool holder only. y ARBOR TYPE Type Corner Radius Order Number Stock Teeth C H :0 A.R : R.R : Dimensions T : I : Tool Weight D1 Set Bolt Geometry &40 HFF08043H z &50, &63 HSC10030H & H x & H &125 MBA20040H c Max.Depth of Cut Max. Allowable Revolution (min -1 ) Type(Fig.) z x c Re R D1 D9 L7 D8 D12 W1 L8 D11 (kg) Clamp Screw Wrench Anti-seize Lubricant AXD A02RA s TS3SB TKY08D MK1KS -040A03RA a TS3SB TKY08D MK1KS A02RA s TS3SB TKY08D MK1KS -050A04RA a TS3SB TKY08D MK1KS A05RA a TS3SB TKY08D MK1KS -080A05RA a TS3SB TKY08D MK1KS -100A06RA a TS3SB TKY08D MK1KS -125B07RA a TS3SB TKY08D MK1KS AXD A02RB s TS3SB TKY08D MK1KS -040A03RB a TS3SB TKY08D MK1KS A02RB s TS3SB TKY08D MK1KS -050A04RB a TS3SB TKY08D MK1KS A05RB a TS3SB TKY08D MK1KS -080A05RB a TS3SB TKY08D MK1KS -100A06RB a TS3SB TKY08D MK1KS -125B07RB a TS3SB TKY08D MK1KS (Note 1) The maximum allowable spindle speeds are set to ensure tool and insert stability. (Note 2) When using the tool at high spindle speeds, ensure that the tool and arbor are correctly balanced. (Note 3) Note for inserts with a corner radius of 1.6 and above, as corner radius increases the dimension decreases. Clamp Torque (N m) : TS3SB=1.5 A Type B Type XDGX1750pp PDpR-pp 4

6 For Machining of Aluminium and Titanium Alloys INSERTS Work Material She N S Aluminium Alloy Titanium Alloy Order Number Class Honing Stock Coated Carbide LC15TF MP9120 TF15 Cutting Conditions (Guide): :Stable Cutting :General Cutting :Unstable Cutting Honing: F :Sharp E :Round Dimensions L4 S1 F1 Re XDGX175004PDFR-GL G F s a PDFR-GL G F s a PDFR-GL G F s s PDFR-GL G F s a PDFR-GL G F s a PDFR-GL G F s s PDFR-GL G F s a PDFR-GL G F s s PDFR-GL G F s a PDFR-GL G F s a XDGX175004PDER- G E a PDER- G E a PDER- G E a PDER- G E a PDER- G E a PDER- G E a PDER- G E a PDER- G E a PDER- G E a PDER- G E a XDGX175004PDFR- G F a PDFR- G F a PDFR- G F a PDFR- G F a PDFR- G F a PDFR- G F a PDFR- G F a PDFR- G F a PDFR- G F a PDFR- G F a F1 30 L4 Geometry Re S1 20 y Holder And Corner Radius Combination Holder A Type Holder AXD4000 pppppppa AXD4000RppppppppA B Type Holder AXD4000 pppppppb AXD4000RppppppppB Applicable Corner R (Re) R0.4 R0.8 R1.2 R1.6 R2.0 R2.4 R3.0 R3.2 R4.0 R5.0 XDGX XDGX XDGX XDGX XDGX XDGX XDGX XDGX XDGX XDGX PDpR-pp PDpR-pp PDpR-pp PDpR-pp PDpR-pp PDpR-pp PDpR-pp PDpR-pp PDpR-pp PDpR-pp Please note that there is no compatibility between an insert for A type holder and for B type holder. 5 a : Inventory maintained. (10 inserts in one case)

7 AXD4000 Selection of insert It is necessary to choose the best insert according to the cutting conditions and the cutting environment. 1st recommendation for stable cutting conditions is the GL breaker. Selection of insert according to the feed per tooth and the required cutting depth 15 ae D Selection of insert according to the width of cut and the required cutting depth GL 3D/4 10 GL 5 D/ fz(mm/t) 0 D/2 1st recommendation for machining aluminium alloys is GL breaker. Under high-load conditions such as deep cutting or high feed cutting, it is advisable to use breaker. ae Selection of insert according to cutting edge type Sharp cutting edge Sharp cutting edge PVD coating and Round-type honing GL TF15/LC15TF TF15 MP9120 Low cutting resistance Tougher cutting edge Tougher cutting edge & wear resistance Machining of difficult-to-cut materials & aluminium Selection of insert according to wear resistance Wear resistance Welding resistance GL LC15TF MQL & Dry cutting MP9120 Super high speed cutting High SI (Cast aluminium) Heavy interrupted machining Cutting speed GL TF15 TF15 Fracture resistance Feed per tooth, Intermittency 6

8 For Machining of Aluminium and Titanium Alloys RECOMMENDED CUTTING CONDITIONS N S Work Material Grade Breaker Aluminium Alloy (A6061, A7075) Aluminium Alloy (A6061, A7075) Aluminium Alloy (AC4B) Aluminium Alloy (ADC12, A390) Titanium Alloy (Ti6Al4V) Si<5% Si<5% 5%<Si<10% Si>10% TF15 LC15TF TF15 MP9120 MP9120 MP9120 GL Cutting Speed vc (m/min) 1000 ( ) 1000 ( ) 200 ( ) 40 (30 60) Cutting Width Depth of Cut ae <0.25 D1 <0.5 D1 <0.75 D1 D1 <0.25 D1 <0.5 D1 <0.75 D1 D1 <0.25 D1 <0.5 D1 <0.75 D1 D1 <0.25 D1 <0.5 D1 <0.75 D1 D1 Feed per Tooth (mm/tooth) Cutting Edge Diameter D1 &20 &25 &28 &32 &35 &40 &50 &125 <5 <0.05 <0.25 <10 <0.05 <0.2 <14.5 <0.05 <0.15 <5 <0.05 <0.25 <10 <0.2 <14.5 <0.15 <5 <0.05 <0.25 <10 <0.2 <14.5 <0.15 <5 <0.05 <0.25 <10 <14.5 <5 <0.05 <0.35 <0.35 <0.4 <0.4 <10 <0.05 <0.3 <0.3 <0.35 <0.35 <14.5 <0.05 <0.25 <0.25 <0.3 <0.3 <5 <0.05 <0.35 <0.35 <0.35 <0.4 <10 <0.3 <0.3 <0.3 <0.35 <14.5 <0.2 <0.25 <0.25 <0.3 <5 <0.05 <0.3 <0.3 <0.3 <0.35 <10 <0.25 <0.25 <0.25 <0.3 <14.5 <0.2 <0.2 <0.2 <0.25 <5 <0.05 <0.25 <0.25 <0.3 <0.35 <10 <14.5 <5 <0.05 <0.35 <0.35 <0.4 <0.4 <10 <0.05 <0.3 <0.3 <0.35 <0.35 <14.5 <0.05 <0.25 <0.25 <0.3 <0.3 <5 <0.05 <0.35 <0.35 <0.35 <0.4 <10 <0.3 <0.3 <0.3 <0.35 <14.5 <0.2 <0.25 <0.25 <0.3 <5 <0.05 <0.3 <0.3 <0.3 <0.35 <10 <0.25 <0.25 <0.25 <0.3 <14.5 <0.2 <0.2 <0.2 <0.25 <5 <0.05 <0.25 <0.25 <0.3 <0.35 <10 <14.5 <5 <0.05 <0.1 <10 <0.05 <0.1 <14.5 <0.05 <0.1 <5 <0.05 <0.08 <0.1 <0.1 <0.1 <10 <0.08 <0.1 <0.1 <0.1 <14.5 <0.08 <0.1 <0.1 <0.1 <5 <0.05 <0.05 <0.08 <0.1 <0.1 <10 <0.05 <0.08 <0.1 <0.1 <14.5 <0.05 <0.08 <0.1 <0.1 <5 <0.05 <0.05 <0.05 <0.05 <0.05 <10 <14.5 (Note 1) The above cutting conditions are determined based on high workpiece and machine rigidity, where no vibration occurred. If vibrations occur make adjustments according to the machining conditions. (Note 2) Note, vibrations may occur in the following conditions. When using long tool overhang. When pocket machining corner radii. When the workpiece has poor clamping rigidity or when the machine rigidity or workpiece rigidity is low, vibrations can occur easily, if so, reduce cutting conditions such as width and depth of cut and feed per tooth. 7

9 y Ramping/Helical milling Ramping L Helical milling Pitch (P) Blind holes, Flat bottom Pitch (P) Through holes L= tan % % RAMPING/HELICAL CUTTING D1 D1 D1 Ramping Helical Milling (Blind Hole, Flat Bottom) Helical Milling Corner Holder Diameter Radius Maximum Maximum Pitch Minimum Hole Diameter Maximum Pitch Minimum Hole Diameter Type D1 Minimum Distance Maximum Hole Diameter Maximum Pitch P Re Ramping Angle P max. WWWDH min. P max. DH min. L DH max. max A type (Note) The recommended ramping feed is 0.05mm/tooth or under. 1) Using the maximum ramping angle, the distance to reach the maximum depth of cut is as follows: L= (maximum depth of cut /tan %). Maximum depth of cut A type is 15.5mm, B type is 14.8mm. 2) Corner radius of 1.2mm. For other corner radii, use the following formula. {(cutting edge diameter D1) (corner radius Re) 0.25} 2 3) Corner radius of 2.4mm. For other corner radii, use the following formula. {(cutting edge diameter D1) (corner radius Re) 0.25} 2 4) Corner radius of 3.2mm. For other corner radii, use the following formula. {(cutting edge diameter D1) (corner radius Re) 0.25} 2 (DH) (DH) 8

10 For Machining of Aluminium and Titanium Alloys Holder Type B type Diameter D Corner Radius Re Maximum Ramping Angle Ramping Helical Milling (Blind Hole, Flat Bottom) Helical Milling Minimum Distance L Maximum Pitch Maximum Hole Diameter Minimum Hole Diameter P max. DH max. DH min. Maximum Pitch P max. Minimum Hole Diameter DH min. Maximum Pitch P max (Note) The recommended ramping feed is 0.05mm/tooth or under. 1) Using the maximum ramping angle, the distance to reach the maximum depth of cut is as follows: L= (maximum depth of cut /tan %). Maximum depth of cut A type is 15.5mm, B type is 14.8mm. 2) Corner radius of 1.2mm. For other corner radii, use the following formula. {(cutting edge diameter D1) (corner radius Re) 0.25} 2 3) Corner radius of 2.4mm. For other corner radii, use the following formula. {(cutting edge diameter D1) (corner radius Re) 0.25} 2 4) Corner radius of 3.2mm. For other corner radii, use the following formula. {(cutting edge diameter D1) (corner radius Re) 0.25} 2 y Max.Drilling Depth Type A type B type Corner Radius Re Max.Drilling Depth Cutting Edge Diameter D1 &20 &25 &28 &32 &35 &40 & AXD4000 can be effectively used for pocket machining without the need for a prepared hole. 9

11 MULTI FUNCTIONAL MILLING FOR ALUMINIUM ALLOY AXD7000 Finishing L7 L8 Roughing Fig. 1 ød12 ød9 Fig. 2 Light Alloy Cast Iron Carbon Steel Alloy Steel Stainless Steel Hardened Steel ø50 ø63 ø80 ø100 W1 ø125 L7 L8 ød12 ød9 W1 y Arbor Type C H :0 A.R :+11 R.R : T : I :+11 &50, &63 HSC10030H & H & H z &125 MBA20040H x -063A03RA a TS4SBL TKY15D MK1KS -080A04RA a TS4SBL TKY15D MK1KS -100A05RA a TS4SBL TKY15D MK1KS -125B06RA a TS4SBL TKY15D MK1KS AXD A03RB a TS4SBL TKY15D MK1KS -063A03RB a TS4SBL TKY15D MK1KS -080A04RB a TS4SBL TKY15D MK1KS -100A05RB a TS4SBL TKY15D MK1KS -125B06RB a TS4SBL TKY15D MK1KS z x XDGX2270pp PDFR-GL ød1 ød4 ød8 ød11 ød1 ød8 ød1 Type A Type B Type Corner Radius Order Number Stock Teeth Dimensions Cutter Diameter D1 Tool Weight Max.Depth of Cut Max. Allowable Revolution (min -1 ) Set Bolt Right hand tool holder only. Geometry Re R Clamp D1 D9 L7 D8 D12 W1 L8 D11 (kg) Screw AXD A03RA a TS4SBL TKY15D MK1KS Type(Fig.) Wrench Anti-seize Lubricant L2 y SHANK TYPE Type A Type B Type Corner Radius Order Number Stock Teeth Dimensions 402SA42SA a TS4SBL TKY15D MK1KS AXD7000R322SA32SB a TS4SB TKY15D MK1KS 402SA42SB a TS4SBL TKY15D MK1KS (Note 1) The maximum allowable revolutions are set to ensure tool and insert stability. (Note 2) When using the tool at high spindle speeds, ensure that the tool and chuck are correctly balanced. (Note 3) Note for inserts with a corner radius of 3.0 and above, as corner radius increases the and L2 dimensions decreases. Clamp Torque (N m) : TS4SB=3.5, TS4SBL=3.5 Max.Depth of Cut Max. Allowable Revolution (min -1 ) Re R D1 L2 D4 Clamp Screw Wrench Anti-seize Lubricant 0.8 AXD7000R322SA32SA a TS4SB TKY15D MK1KS Right hand tool holder only. XDGX2270pp PDFR-GL a : Inventory maintained. 10

12 HSK63A ø D 1 ø63 L2 y HSK63A Monoblock Type A Type Corner Radius Order Number Stock Teeth Dimensions 04002A-H63A a TS4SBL TKY15D MK1KS 05003A-H63A a TS4SBL TKY15D MK1KS (Note 1) The maximum allowable spindle speeds are set to ensure tool and insert stability. (Note 2) When using the tool at high spindle speeds, ensure that the tool and arbor are correctly balanced. (Note 3) Note for inserts with a corner radius of 3.0 and above, as corner radius increases the and L2 dimensions decrease. (Note 4) There is no hole for a data chip. Clamp Torque (N m) : TS4SB=3.5, TS4SBL=3.5 Max.Depth of Cut Max. Allowable Revolution (min -1 ) Re R Clamp D1 L2 Screw Wrench Anti-seize Lubricant AXD7000R03202A-H63A a TS4SB TKY15D MK1KS Right hand tool holder only. XDGX2270pp PDFR-GL 11

13 INSERTS Work Material She N Aluminium Alloy Order Number Class Honing LC15TF Stock Coated Carbide TF15 Cutting Conditions (Guide): :Stable Cutting :General Cutting :Unstable Cutting Dimensions L4 S1 F1 Re XDGX227008PDFR-GL G F s a PDFR-GL G F s a PDFR-GL G F s a PDFR-GL G F s a PDFR-GL G F s a PDFR-GL G F s a PDFR-GL G F s a F1 30 L4 Geometry Re S1 Honing: F :Sharp 20 y Holder And Corner Radius Combination Holder Applicable Corner R (Re) XDGX PDFR-GL XDGX PDFR-GL A Type Holder AXD7000 pppppppa AXD7000RppppppppA AXD7000RpppppA-H63A XDGX PDFR-GL XDGX PDFR-GL XDGX PDFR-GL AXD7000 pppppppb AXD7000RppppppppB R0.8 R1.6 R2.0 R3.0 R3.2 R4.0 R5.0 XDGX PDFR-GL B Type Holder XDGX PDFR-GL Please note that there is no compatibility between an insert for A type holder and that of for B type holder. N RECOMMENDED CUTTING CONDITIONS Work Material Grade Breaker Aluminium Alloy LC15TF TF15 GL Cutting Speed vc (m/min) 1000 ( ) Cutting Width ae <0.25 D1 <0.5 D1 <0.75 D1 <D1 Cutting Feed (mm/tooth) Depth Cutting Edge Diameter D1 &32 &40 &50 &125 <5 <0.35 <0.40 < <0.30 <0.35 < <0.25 <0.30 < <0.20 <0.25 <0.25 <5 <0.35 <0.35 < <0.30 <0.30 < <0.25 <0.25 < <0.20 <0.20 <0.25 <5 <0.30 <0.30 < <0.25 <0.25 < <0.20 <0.20 < <0.15 <0.15 <0.20 <5 <0.25 <0.30 < <0.20 <0.25 < <0.15 <0.20 <0.25 <0.10 <0.15 <0.20 (Note 1) The above cutting conditions are determined based on high workpiece and machine rigidity, where no vibration occurred. If vibrations occur make adjustments according to the machining conditions. (Note 2) Note, vibrations may occur in the following conditions. When using long tool overhang. When pocket machining corner radii. When the workpiece has poor clamping rigidity or when the machine rigidity or workpiece rigidity is low, vibrations can occur easily, if so, reduce cutting conditions such as width and depth of cut and feed per tooth. a : Inventory maintained. 12

14 y Ramping/Helical milling a Ramping L a Helical milling Pitch (P) Blind holes, Flat bottom Pitch (P) Through holes L= tan % % RAMPING/HELICAL CUTTING Holder Type A type B type Cutting Edge Diameter D1 Maximum Ramping Angle % D1 D1 D1 Ramping Helical Milling (Blind Hole, Flat Bottom) Helical Milling (Through Hole) Minimum Distance L Maximum Hole Diameter DH max. Maximum Pitch P max (Note) The recommended ramping feed is 0.05mm/tooth or under. 1) Using the maximum ramping angle, the distance to reach the maximum depth of cut is as follows: L= (maximum depth of cut /tan %). Maximum depth of cut A type is 21mm, B type is 20.4mm. 2) The maximum diameter when machining a blind hole with a flat face using a corner radius of 0.8mm for A type and 4mm for B type. For other corner radii, use the below formula. {(cutting edge diameter D1) (corner radius Re) 0.3)} 2 3) The minimum diameter when machining a blind hole with a flat face using a corner radius of 0.8mm for A type and 4mm for B type. For other corner radii, use the below formula. {(cutting edge diameter D1) (corner radius Re) (Width of wiper edge F1) 0.1)} 2 (DH) Minimum Hole Diameter DH min. Maximum Pitch P max. Minimum Hole Diameter DH min. (DH) Maximum Pitch P max. y Max.Drilling Depth Type A type B type Corner R Re Max.Drilling Depth 5 4 AXD7000 can be effectively used for pocket machining without the need for a prepared hole. 13

15 CAUTION FOR USE Procedure for attaching inserts 1) Use an air blower or brush to clean the insert seats before attaching the inserts. 2) Holding the inserts firmly against the insert seat, tighten the clamp screws using the wrench provided. 3) Tighten the clamp screws in the order shown in Figure 2. 4) Apply anti-seize lubricant to the clamp screws and tighten them with the torque specified. The specified torque is as follows. AXD N m(2.58ft lb) AXD N m(1.11ft lb) 5) Clamp screws are important parts from the viewpoint of safety. Use clamp screws with the correct part number. If the spindle speed is equal to or higher than the values shown in Table 2, it is recommended to replace the clamp screws with new ones when changing inserts. Type D1 Clamp Screwr Length L AXD4000 AXD7000 ø20 ø25 ø125 ø32 ø40 ø125 TS3SBS TS3SB TS4SB TS4SBL L Fig.1 First Second 6) Check that there are no gs between the insert and the seat before use. Procedure for attaching the cutter to an arbor 1) Before attaching the cutter to the arbor, carefully clean the socket and end of the cutter and the end of the arbor. 2) Place the cutter on the arbor and tighten the attachment bolt provided. See the table below for the tightening torque. 3) The attachment bolt provided with the AXD is a special bolt for through coolant. Take care not to lose it. AXD4000 AXD7000 Geometry Set Bolt (N m) D1 Fig Geometry Set Bolt (N m) D1 Fig HFF08043H 11 ø40 1 HSC10030H 40 ø50, ø63 2 HSC12035H 80 ø80 2 HSC16040H 150 ø100 2 MBA20040H 320 ø120 3 HSC10030H 40 ø50, ø63 1 HSC12035H 80 ø80 1 HSC16040H 150 ø100 1 MBA20040H 320 ø120 2 Table 1 Max. Allowable Revolution AXD4000 AXD7000 Diameter D1 Max. Revolution (min -1 ) Diameter D1 Max. Revolution (min -1 ) ø25 ø32 ø40 ø50 ø63 ø80 ø100 ø ø32 ø40 ø50 ø63 ø80 ø100 ø Even when operating under the maximum allowable spindle speed, if the spindle speed is equal to or higher than the values shown in table 2, it is recommended that the balance quality (with the arbor or milling chuck) conforms to G6.3 or betterbased on ISO1940. It is also recommended to replace the clamp screws with new ones when changing inserts. Furthermore,ensure to use machines that are provided with safety measures in case of cutter breakage. (Note) The balance quality of the holder (without inserts and clamp screws) is G6.3 or better at 10,000min -1. Table 2 Maximum spindle speed when balancing with the arbor or milling chuck has not been achieved AXD4000 AXD7000 Diameter D1 Max. Revolution (min -1 ) Diameter D1 Max. Revolution (min -1 ) ø25 ø32 ø40 ø50 ø63 ø80 ø100 ø ø32 ø40 ø50 ø63 ø80 ø100 ø When setting the spindle speed, take into consideration the maximum allowable spindle speed of the arbor or milling chuck. Use the specified set bolt when using the arbor type with through coolant. The inserts have sharp cutting edges and handling them with bare hands may cause injuries. Always wear safety gloves whenhandling the indexable inserts. 14

16 For Machining of Aluminium and Titanium Alloys Technical Data Excellent Wall Accuracy Specially designed G-class inserts with a helical cutting edge for excellent wall accuracy. Depth of cut per pass δ Wall surface accuracy δ (!m) Competitor AXD4000 Wall surface accuracy δ (!m) Competitor AXD Depth of cut per pass Depth of cut per pass Tool Grade Workpiece Cutting speed Feed per tooth Width of cut Wet cutting : AXD4000R403SA42SA : XDGX175008PDFR-GL : TF15 : 7075 : 1000m/min : 0.2mm/tooth : 3mm Tool Grade Workpiece Cutting speed Feed per tooth Width of cut Wet cutting : AXD7000R402SA42SA : XDGX227008PDFR-GL : TF15 : 7075 : 2500m/min : 0.2mm/tooth : 3mm Low Resistance s An optimised helical flank and flank angle offers cutting edge strength and provides a large rake angle to reduce cutting resistance. Additionally a convex cutting edge is incorporated to ensure effective chip flow. Tool Grade Workpiece : AXD A04RA AXD A03RA : XDGX175008PDFR-GL XDGX227008PDFR-GL : TF15 : 7075 Cutting speed Feed per tooth Width of cut Depth of cut Single tooth Wet cutting : 1000m/min : 0.2mm/tooth : 25mm : 10mm Power consumption (N) Cutting resistance AXD Competitor A Competitor B AXD7000 Competitor A Competitor B 0 0 Principal force Feed force Back force Principal force Feed force Back force Power consumption (N) Convex cutting edge Helical flank Comparison of surface finishes Competitor AXD4000- Cutting performance when milling Ti6Al4V Competitor AXD4000-(MP9120) Ra 0.675µm Rz 3.725µm Ra 0.120µm Rz 1.132µm After 0.4m of machining After 0.8m of machining Tool Workpiece Cutting speed Feed per tooth : AXD A04RA Width of cut : AXD4000-GL Depth of cut : 7075 Single tooth : 1000m/min Internal coolant : 0.15mm/tooth BT40 : 30mm : 0.5mm Tool Grade Workpiece Cutting speed Feed per tooth : AXD A04RA : XDGX175004PDER- : MP9120 : Ti-6Al-4V : 30m/min : 0.1mm/tooth Width of cut Depth of cut Single tooth Internal/External coolant : 40mm : 2mm 15

17 Cutting Performance Cutting of aluminium alloy cast iron : Si content 9% 2.3 times longer tool life due to tougher cutting edge & PVD coating MP9120 Competitor Competitor Tool life (min) <Cutting conditions> Workpiece : aluminium alloy cast iron : Si content 9% Tool : AXD A02RA : XDGX175008PDER- Cutting speed : 960m/min Feed : 0.1mm/tooth Depth of cut : =6.0mm ae=33mm Wet cutting 16

18 For Machining of Aluminium and Titanium Alloys APPLICATION EXAMPLES Tool AXD A02RA (Grade) XDGX175030PDFR-GL(TF15) AXD4000R322SA32SA XDGX175030PDFR-GL(TF15) Workpiece Cutting Conditions Spindle speed (min -1 ) Cutting Speed (m/min) Feed per Tooth (mm/tooth) Depth of Cut Width of Cut Metal Removal Rate (cm 3 /min) Coolant Wet Wet Machine Spindle Type M/C-HSK80F M/C-BT50 Result Although tool overhang was significant, the low cutting resistance compared with conventional products enabled stable milling. Compared with conventional products, tool rigidity is high, obtaining an excellent surface finish. Tool (Grade) AXD4000R12507EA XDGX175008PDFR-GL(TF15) AXD A03RB XDGX227040PDFR-GL(TF15) Workpiece Cutting Conditions Spindle speed (min -1 ) Cutting Speed (m/min) Feed per Tooth (mm/tooth) Depth of Cut Width of Cut Metal Removal Rate (cm 3 /min) Coolant Wet Machine Spindle Type M/C-BT50 M/C-HSK63/80A Result Compared with conventional products, cutting resistance is low, and feed rate per tooth was improved by 20%. MQL AXD displayed lower cutting resistance and achieved a high metal removal rate of up to 9720cm 3 /min. Please note that the machining performed in the plication examples is dependent on the rigidity of the machine used and the rigidity of the workpiece and clamping. 17

19 Tool (Grade) AXD A03RA XDGX227008PDFR-GL(TF15) AXD7000R402SA42SA XDGX227008PDFR-GL(TF15) Workpiece Cutting Conditions Spindle speed (min -1 ) Cutting Speed (m/min) Feed per Tooth (mm/tooth) Depth of Cut Width of Cut Metal Removal Rate (cm 3 /min) Coolant Wet Wet Machine Spindle Type M/C-BT50 M/C-HSK63A Result Clamping rigidity of the inserts was higher than a conventional product, thus allowing stable 5-axis machining. AXD achieved excellent results with a vertical wall accuracy of under 0.007mm. Tool (Grade) Ti-6Al-4V AXD A04RA XDGX175008PDER-(MP9120) AlSi10Mg AXD4000R252SA25SA XDGX175008PDER-(MP9120) Workpiece Cutting Conditions Spindle speed (min -1 ) Cutting Speed (m/min) Feed per Tooth (mm/tooth) Depth of Cut Width of Cut Coolant Wet External coolant Machine Type Vertical 3 axis Vertical Result AXD achieved double tool life compared to conventional products. Since aluminium alloy containing Si tends to produce tool damage, the coated insert MP9120 achieved double tool life compared to non-coated products. 18

20 AXD For Machining of Aluminium and Titanium Alloys AXD (XXX) Printed in Germany