Indexable endmill for high precision finishing

Size: px

Start display at page:

Download "Indexable endmill for high precision finishing"

Rudolf Riley
5 years ago
Views:

1 MillLine Tungaloy Report No. 431-US BALLFINISH-NOSE Indexable endmill for high precision finishing

2 ACCELERATED MACHINING

3 MillLine Excellent surface finish and stable machining due to secure clamping and minimum run out

New indexable endmill for die & mold and aerospace industries.

portion of the insert screwhole and directs the clamping forces in a specific direction ensuring

Unique coolant delivery system Asymmetric shape of the insert and directed clamping force maintains

- Coolant channel on the insert surface delivers coolant to the cutting edge in three directions.

4 New indexable endmill for die & mold and aerospace industries. Secure clamping mechanism Cutting force F F Cutting force F Clamping force The screw contacts the flat portion of the insert screwhole and directs the clamping forces in a specific direction ensuring reliability in clamping. This also improves rigidity and reduces run-out. Unique coolant delivery system Asymmetric shape of the insert and directed clamping force maintains centrality of the insert under 3 dimensional cutting force. - Coolant channel on the insert surface delivers coolant to the cutting edge in three directions. - Excellent chip evacuation and cooling effect provides good surface finish and long tool life in machining of hardened steel. Two insert varieties Ball nose type: ZFBU Radius type: ZFRU MJ -For general purpose -First choice ML -For lower cutting force - Suitable for finishing and three dimensional milling of die & mold - Applicable for a wide range of operations MJ - Suitable for finishing of die & mold - Designed for milling corners & shoulders 4 BallFinishNose

ACCELERATED MACHINING Versatile grade AH725 Steel Stainless Cast iron Hard Materials For steel, stainless steel, cast iron and

$0 (Ti, Al)N 2 Features For general purpose Good balance between wear and fracture First choice Workpiece material Hardness$ Carbon steel, Alloy steel Stainless steel Prehardend steel, Die & mold tool steel High hardened steel Cast iron 85-280 HB

Carbon steel, Alloy steel Stainless steel Prehardend steel, Die & mold tool steel High hardened steel Cast iron 85-280 HB

520 mm) 0.0002" (5 µm) Ball nose insert has high radius accuracy within 0.0002" and precisely meets dimensional requirements.

375") Good surface finish Ball nose type ZFBU075R00-MJ Radius type ZFRU075R006-MJ Roughness (µm) Roughness (µm) 5.0 Ra: 0.

5 ACCELERATED MACHINING Versatile grade AH725 Steel Stainless Cast iron Hard Materials For steel, stainless steel, cast iron and hard materials Application Grade Substrate Coating layer Application code AH725 P20 - P30 Relative density Hardness HRA T. R. S. (GPa) Main Composition Thickness (μm) (Ti, Al)N 2 Features For general purpose Good balance between wear and fracture First choice Workpiece material Hardness Carbon steel, Alloy steel Stainless steel Prehardend steel, Die & mold tool steel High hardened steel Cast iron HB HB HRC HRC HB AH725 Excellent machining accuracy High radius accuracy " (9.525 mm) " (9.520 mm) " (5 µm) Ball nose insert has high radius accuracy within " and precisely meets dimensional requirements. Shank: EBFU075T100S0700 Insert: ZFBU075R00-MJ Tool diameter: ødc = ø0.750" (rε = 0.375") Good surface finish Ball nose type ZFBU075R00-MJ Radius type ZFRU075R006-MJ Roughness (µm) Roughness (µm) 5.0 Ra: 0.37 µm, Rz: 3.05 µm Length (in) 5.0 Ra : 0.25 µm, Rz : 1.43 µm Length (in) Shank : EBFU075T100S0700 Workpiece material: 1045 Cutting speed: Vc = 656 sfm Feed per tooth: fz = ipt Depth of cut: ap =0.020" Coolant: Wet 5

6 ENDMILLS - STEEL SHANK BallFinishNose EBF ødc L øds Fig-1 Lf ls ødc L øds Fig-2 L2 Lf a ls ødc øds ls Lf L L2 a Fig. Insert EBFU037T050S ZF*U037 EBFU037T062S ZF*U037 EBFU050S050S ZF*U050 EBFU050T062S ZF*U050 EBFU062T075S ZF*U062 EBFU062T075S ZF*U062 EBFU075T100S ZF*U075 EBFU075T100S ZF*U075 EBFU100T125S ZF*U100 EBFU100T125S ZF*U100 EBFU125S125S ZF*U125 SPARE PARTS Clamping Screw Torx Bit Wrench Grip Mono block type wrench EBFU TS30F100A - - T10D EBFU TS40F120A - - T15D EBFU TS50F160A - - T-T20 EBFU TS60F200A BLDT25/M7 SW6-T - EBFU TS70F250A BLDT25/M7 SW6-T - EBFU TS70F300A - - T-T30 6 BallFinishNose

7 ACCELERATED MACHINING ENDMILLS - CARBIDE SHANK BallFinishNose EBF ødc øds Lf L ls ødc øds ls Lf L Insert EBFU037S037C ZF*U037 EBFU037S037C ZF*U037 EBFU050S050C ZF*U050 EBFU050S050C ZF*U050 EBFU062S062C ZF*U062 EBFU062S062C ZF*U062 EBFU075S075C ZF*U075 EBFU075S075C ZF*U075 EBFU100S100C ZF*U100 EBFU100S100C ZF*U100 EBFU125S125C ZF*U125 SPARE PARTS Clamping Screw Torx Bit Wrench Grip Mono block type wrench EBFU TS30F100A - - T10D EBFU TS40F120A - - T15D EBFU TS50F160A - - T-T20 EBFU TS60F200A M7/BLDT25 T-SW6 - EBFU TS70F250A M7/BLDT25 T-SW6 - EBFU TS70F300A - - T-T30 7

ENDMILLS - MODULAR TYPE BallFinishNose HBFM HBFM Indexable endmills with TungFlex threaded adaptation for high precision finish A C Ts T R ødc ød3 R R Lf A L6 A - A cross section ødc ødc L6 L 6 Lf L

8 ENDMILLS - MODULAR TYPE BallFinishNose HBFM HBFM Indexable endmills with TungFlex threaded adaptation for high precision finish A C Ts T R ødc ød3 R R Lf A L6 A - A cross section ødc ødc L6 L 6 Lf L f C C T T ø D3 TsTs* Air Air hole Hole Insert Insert HBFM10M M6 M6 with with ZF*M ZF*U037 HBFM12M06 HBFM12M M6 M6 with with ZF*M ZF*U050 HBFM12M M8 with ZF*U050 HBFM12M M8 with ZF*M HBFM16M M8 with ZF*U062 HBFM20M10 HBFM16M M8 M10 with with ZF*M ZF*U075 HBFM25M12 HBFM20M M10M12 with with ZF*M ZF*U100 HBFM32M16 HBFM25M M12M16 with with ZF*M ZF*U125 HBFM30M M16 with ZF*M HBFM32M M16 with ZF*M SPARE PARTS Clamping screw screw Torx Torx bit Grip Grip Wrench HBFM10... TS 30F100A T-10D T-10D HBFM12... TS 40F120A - - T-15D HBFM12... TS 40F120A - - T-15D HBFM16... TS 50F160A BT20S H-TB2W - HBFM20... HBFM16... TS 50F160A 60F200A BT20S BLDT25/M7 H-TB2W H-TB2W - - HBFM25... HBFM20... TS 70F250A TS 60F200A BLDT25/M7 BLDT25/M7 H-TB2W H-TB2W - - HBFM32... TS 80F300A - - T-T30 HBFM25... TS 70F250A BLDT25/M7 H-TB2W - * Metric thread sizes * Metric thread HBFM30... sizes TS 80F300A - - T-T30 HBFM32... TS 80F300A - - T-T30 8 BallFinishNose

9 ACCELERATED MACHINING INSERT ZFBU-MJ T ap ød rε Max. ap ød T rε AH725 ZFBU037R00-MJ ZFBU050R00-MJ ZFBU062R00-MJ ZFBU075R00-MJ ZFBU100R00-MJ ZFBU125R00-MJ P M K N H First choice ZFBU-ML T ap ød rε Max. ap ød T rε AH725 ZFBU037R00-ML ZFBU050R00-ML ZFBU062R00-ML ZFBU075R00-ML ZFBU100R00-ML ZFBU125R00-ML P M K N H First choice 9

10 INSERT ZFRU - MJ 3º T ap d rε Max. ap ød T rε AH725 ZFRU037R003-MJ ZFRU050R003-MJ ZFRU050R006-MJ ZFRU050R012-MJ ZFRU062R003-MJ ZFRU062R006-MJ ZFRU062R012-MJ ZFRU075R003-MJ ZFRU075R006-MJ ZFRU075R012-MJ ZFRU100R003-MJ ZFRU100R006-MJ ZFRU100R012-MJ ZFRU125R003-MJ ZFRU125R006-MJ ZFRU125R012-MJ P M K N H First choice 10 BallFinishNose

11 ACCELERATED MACHINING STANDARD CUTTING CONDITIONS ISO Workpiece materials Hardness Grades Recommended Selection criteria Chipbreaker Max. axial depth of cut ap (in) Cutting speed Vc (sfm) Feed per tooth: fz (ipt) ødc (in) ø0.375 ø0.500 ø0.625 ø0.750 ø1.000 ø1.250 Low carbon steel, alloy steel HB AH725 First choice MJ 0.04D HB AH725 For wear ML 0.04D High carbon steel, alloy steel HB AH725 First choice MJ 0.03D HB AH725 For wear ML 0.03D Prehardened steel Die & mold tool steel HRC AH725 First choice ML 0.03D HRC AH725 For impact MJ 0.03D Stainless steel HB AH725 First choice ML 0.03D HB AH725 For impact MJ 0.03D Cast iron HB AH725 First choice MJ 0.04D HB AH725 For wear ML 0.04D Aluminum - AH725 First choice ML 0.03D AH725 For impact MJ 0.03D High hardened steel HRC AH725 First choice ML 0.02D HRC AH725 For impact MJ 0.02D Standard cutting conditions should be used only as references for each workpiece material. - These conditions are based on the use of steel shank. For carbide shank, depth of cut and feed per tooth can be increased by 20-30%. How to clamp the insert 1. Clear chips and dust from the pocket. 2. Place the insert in the pocket. The insert can be placed only in one direction. 3. Tighten the screw while pressing the insert into the pocket. How to check the run-out 1. Clamp the insert on the shank. 2. Clamp the shank on a high precision arbor. 3. Measure the run-out on tool presetter or by dial gauge. Notes: 1. Due to the helical cutting edge, it is important that the run-out is inspected with the insert clamped on the shank. 2. Do not use micrometer or caliper to inspect the insert diameter as inaccurate dimensions may be provided. 11

Practical examples Workpiece type Cutter Insert Grade Carrier

ZFBU050R00-MJ AH725 STAVAX Workpiece material 59.0" 31.5" 7.87" 11.

(ipt) Depth of cut: ap (in) Pick feed: pf (in) Method of machining

039 Profiling Dry M/C, CAT50 Profiling Internal supply,

6 4 2 0 Competitor 50 % longer tool life!

life! BallFinishNose tool life was 50% longer than the competitor's

12 Practical examples Workpiece type Cutter Insert Grade Carrier EBFU075S075C0875 ZFBU075R00-MJ AH725 SKD11 Cylinder EBFU050S050S0437 ZFBU050R00-MJ AH725 STAVAX Workpiece material 59.0" 31.5" 7.87" 11.8" Cutting conditions Cutting speed: Vc (sfm) Feed per tooth: fz (ipt) Depth of cut: ap (in) Pick feed: pf (in) Method of machining Coolant Machine Profiling Dry M/C, CAT50 Profiling Internal supply, water-soluble coolant Vertical M/C, CAT40 Results Cutting time (h) Competitor 50 % longer tool life! Cutitng length (ft) Competitor 54 % longer tool life! BallFinishNose tool life was 50% longer than the competitor's due to high wear. BallFinishNose cutting length was 54% longer than the competitor s due to excellent chip evacuation. 12 BallFinishNose

Check out our other products in of DrillLine!

Economical 3-cutting-edged indexable insert with chip splitter.

cutting force and allowing increased feed rate compared to brazed

.. Available in 5 sizes to cover ødc 16 to 28 mm Tungaloy America,

Fax: +1-888-554-8392 Tungaloy Canada 432 Elgin St.

Fax: +1-519-758-5791 www.tungaloy.com/ca Tungaloy de Mexico S.A.

AGS, Mexico 20290 Phone:+52-449-929-5410 Fax:+52-449-929-5411 www.

13 Check out our other products in of DrillLine! Deep hole drilling with remarkable productivity and stability Economical 3-cutting-edged indexable insert with chip splitter. Chip splitters produce small chips for smooth evacuation, reducing cutting force and allowing increased feed rate compared to brazed gundrills. TOHT... Available in 5 sizes to cover ødc 16 to 28 mm Tungaloy America, Inc N Ventura Drive, Arlington Heights, IL 60004, U.S.A. Inside Sales: Technical Support: Fax: Tungaloy Canada 432 Elgin St. Unit 3, Brantford, Ontario N3S 7P7, Canada Phone: Fax: Tungaloy de Mexico S.A. C Los Arellano 113, Parque Industrial Siglo XXI Aguascalientes, AGS, Mexico Phone: Fax: follow us at: facebook.com/tungaloyamerica t w i t t e r. c o m / t u n g a l o y To see this product in action visit: Distributed by: DOWNLOAD Dr. Carbide App Scan for instant web access Jan (TA)

Double-sided positive insert for semi-finishing to finishing

MillLine Tungaloy Report No. 508-US DOMINI-MILL Double-sided positive insert for semi-finishing to finishing ACCELERATED MACHINING MillLine DoMini-Mill features the advantage of an economical 6-cornered