and AM-CAT-COREV(GB)-11/08 High Performance Indexable Insert Systems
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1 and AM-CAT-COREV(GB)-11/08 High Performance Indexable Insert Systems
2 Allied Maxcut Engineering Co. Limited AMEC Indexable Drill Range The AMEC range of adjustable indexable carbide drills provides the ultimate in versatility as they can be pre-set to cut any diameter hole within their range of 47.75mm to mm. Incorporating two complementary drilling systems, the AMEC Revolution Drill and the, the new range reinforces AMEC s reputation for innovation and delivers an adaptable, high performance drilling solution to meet a range of production needs. The is designed to increase the diameter of an existing hole, while the AMEC Revolution drilling system uses over-centre cutting to drill from solid without the need for a pilot hole. Available in a range of shank styles and capable of drilling to depth up to 5 times diameter. The AMEC Indexable range is a powerful and versatile drilling solution that can deliver high productivity and a low cost per hole in a diversity of applications and industry sectors For additional information on all AMEC products, please visit or contact our Application Engineering department for technical support and assistance on +44 (0)
3 Contents AMEC Revolution Drill TM Features and Benefits Page 2 AMEC Revolution Drill TM Holders, Inserts and Speeds & Feeds Page 3 TM Features and Benefits Page 4 TM Reference Page 5 TM Straight & ABS Page 6 TM DV40 & DV50 Flange Page 7 TM BT40 & BT50 Page 8 TM HSK63A/C & HSK100A/C Page 9 TM Operation & Set Up Procedure Page 10 TM Speeds & Feeds Minimum Pilot Hole Calculation Page 11 Request for Guaranteed Application Page 12
4 Features and Benefits Drills from Solid, no pilot required Revolutionary design allows adjustability up to 5.1mm on diameter Drill s up to 4.5 times diameter Removable cartridges for easy replacement Insert design allows for excellent chip control and aggressive penetration rates Less tool inventory needed for range of diameters The proprietary AM200 coating increases tool life above competitors premium coatings. Setting the Revolution Drill Fixed Cartridge Loosen Mounting on Adjustable Cartridge ADJ Cartridge Set diameter using the adjustment screw Tighten mounting screw, locking cartridge into position. Place the tool in a presetter to ensure correct diameter setting. 2
5 L2 D2 STRAIGHT SHANK ISO 9766 Part Diameter Range Max Drill () Dia (D2) (L2) Cartridges Mounting (1 Pack) Replacements Adjustment (1 Pack) Insert s (10 Pack) R34X22-40M 47.75mm 114mm 136.6mm (Fixed) C34-FIX R34X35-40M to 178mm 200.1mm 40mm 70mm MS-17 AS-16 IS R34X45-40M 50.80mm 228mm 251.0mm C34-ADJ R36X22-40M 50.80mm 127mm 149.2mm (Fixed) R36X35-40M to C36-FIX 197mm 219.1mm 40mm 70mm MS-17 AS-18 IS R36X45-40M 55.88mm 254mm 276.2mm C36-ADJ R38X22-40M 140mm 162.0mm 55.88mm (Fixed) C38-FIX R38X35-40M to 216mm 238.1mm 40mm 70mm R38X45-40M 60.96mm 280mm 301.6mm C38-ADJ MS-17 AS-18 IS R42X22-40M 60.96mm 146mm 171.5mm (Fixed) R42X35-40M to 235mm 260.4mm C42-FIX 40mm 70mm MS-19 AS-18 IS R42X45-40M 66.04mm 298mm 323.9mm C42-ADJ R44x22-40M 66.04mm 159mm 191.0mm (Fixed) R44X35-40M to 254mm 285.0mm 70mm C44-FIX) 40mm 71.12mm MS-19 AS-18 IS C44-ADJ R46X22-40M 71.12mm 172mm 203.0mm (Fixed) R46X35-40M to 267mm 299.9mm 70mm C46-FIX 40mm MS-19 AS-18 IS mm C46-ADJ R48X10-50M 76.20mm 82mm 114.3mm (Fixed) R48X25-50M to C48-FIX 203mm 235.0mm 80mm 50mm MS-21 AS-18 IS mm C48-ADJ R52X10-50M 89mm 127.0mm 81.28mm (Fixed) R52X25-50M 216mm 254.0mm 80mm C52-FIX to 50mm 86.36mm C52-ADJ MS-19 AS-18 IS R54X10-50M 86.36mm 95mm 133.4mm (Fixed) C54-FIX R54X25-50M to 229mm 266.7mm 50mm 80mm MS-19 AS-18 IS mm C54-ADJ R56X10-50M 91.44mm 102mm 146.1mm (Fixed) C56-FIX R56X25-50M to 241mm 285.8mm 50mm 80mm 96.52mm C56-ADJ MS-21 AS-18 IS R58X10-50M 102mm 146.1mm 96.52mm (Fixed) C58-FIX R58X25-50M to 254mm 298.5mm 50mm 80mm 101.0mm C58-ADJ MS-21 AS-18 IS Stock Availability. Stocked Stocked in limited quantities Non-Stocked Standard (6 week lead time) Grade Z55, Coating and Availability - 10 Piece Packs AM200 OP-05T308-H TiN OP-05T308-T Material Material Hardness (BHN) AM200 M/min TiN FEED (mm/rev) Free Machining Steel Low Carbon Steel Medium Carbon Steel Alloy Steel High Strength Alloy Structural Steel Material Material Hardness (BHN) AM200 M/min TiN FEED (mm/rev) High Temperature Alloy Stainless Steel Tool Steel Aluminium (use TiN coated insert) Cast Iron Brass Formulas: mm/min=rpm mm/rev M/min=RPM DIA RPM M/min /DIA The speeds and feeds listed above are considered a general starting point for all applications. Technical assistance is also available for your specific applications through the AMEC Application Engineering Team. Please provide any details about the application to the Application Engineering Team. Accurate information will enable Allied Maxcut s Application Engineers to give you the best possible solution. 3
6 Features and Benefits Opens an existing hole in a single operation Ignores core shifts up to 3.175mm (1/8 ) providing straight and true holes without boring Allows for large amounts of material removal Unique design enables larger holes to be made on lower powered machines Multi-insert design reduces chip size for easy chip evacuation Smooth cutting action and quiet operation in lathes and mills Can be used as a rotating or stationary tool Useable in rough boring operations Replaceable insert cartridges protect your investment Adjustable diameters reduce inventory and cost Special lengths, diameters and shanks available upon request 4
7 Reference OP1-1S-40M Drill Ø Range 1S Short 40M HSK 100A/C 1 ( ) 1L - Long 50M ABS63 2 ( ) BT40 DV40 3 ( ) BT50 DV50 4 ( ) HSK 63A/C Insert OP 05T308 - H Insert Specification Coating H AM200 A - TiAlN N - TiCN T TiN U - Uncoated Cartridge OP1 WC05 Drill Ø Range Cartridge Specification 1 ( ) 2 ( ) 3 ( ) 4 ( ) 5
8 Straight and ABS, Coating and Availability - 10 Piece Packs Grade AM200 TiN TiAN TiCN Z55 OP-05T308-H OP-05T308-T OP-05T308-A OP-05T308-N L2 L2 D2 Metric STRAIGHT SHANK ISO 9766 Imperial D2 STRAIGHT SHANK () (L2) Diameter (D2) Straight (Metric) OP1-1S-40M OP1 SS40M Short OP1-1L-40M OP1 SS40M Long OP2-1S-40M OP2 SS40M Short OP2-1L-40M OP2 SS40M Long OP3-1S-40M OP3 SS40M Short OP3-1L-40M OP3 SS40M Long OP4-1S-50M OP4 SS50M Short OP4-1L-50M OP4 SS50M Long () (L2) Diameter (D2) Straight (Imperial) OP1-1S-SS1.5 OP1 SS 1.50 Short OP1-1L-SS1.5 OP1 SS 1.50 Long OP2-1S-SS1.5 OP2 SS 1.50 Short OP2-1L-SS1.5 OP2 SS 1.50 Long OP3-1S-SS1.5 OP3 SS 1.50 Short OP3-1L-SS1.5 OP3 SS 1.50 Long OP4-1S-SS2.0 OP4 SS 2.00 Short OP4-1L-SS2.0 OP4 SS 2.00 Long ABS 63 Max Drill () ABS63 OP1-1S-ABS63 OP1 ABS63 Short OP1-1L-ABS63 OP1 ABS63 Long OP2-1S-ABS63 OP2 ABS63 Short OP2-1L-ABS63 OP2 ABS63 Long OP3-1S-ABS63 OP3 ABS63 Short OP3-1L-ABS63 OP3 ABS63 Long OP4-1S-ABS63 OP4 ABS63 Short Replacement Cartridges Qty Inserts Required Insert 10 Pack Mounting Adjusting OP1-WC05 2 IS MS-13-4 AS-10-4 OP2-WC05 2 IS MS-15-4 AS-10-4 OP3-WC05 2 IS MS-15-4 AS-12-4 OP4-WC05 3 IS MS-15-4 AS
9 DV40/DV50 Flange, Coating and Availability - 10 Piece Packs Grade AM200 TiN TiAN TiCN Z55 OP-05T308-H OP-05T308-T OP-05T308-A OP-05T308-N DV40 DIN FORM A () DV40 OP1-1S-DV40 OP1 DV40 Short OP1-1L-DV40 OP1 DV40 Long OP2-1S-DV40 OP2 DV40 Short OP2-1L-DV40 OP2 DV40 Long OP3-1S-DV40 OP3 DV40 Short OP3-1L-DV40 OP3 DV40 Long OP4-1S-DV40 OP4 DV40 Short DV50 DIN FORM A () DV50 OP1-1S-DV50 OP1 DV50 Short OP1-1L-DV50 OP1 DV50 Long OP2-1S-DV50 OP2 DV50 Short OP2-1L-DV50 OP2 DV50 Long OP3-1S-DV50 OP3 DV50 Short OP3-1L-DV50 OP3 DV50 Long OP4-1S-DV50 OP4 DV50 Short OP4-1L-DV50 OP4 DV50 Long Replacement Cartridges Qty Inserts Required Insert 10 Pack Mounting Adjusting OP1-WC05 2 IS MS-13-4 AS-10-4 OP2-WC05 2 IS MS-15-4 AS-10-4 OP3-WC05 2 IS MS-15-4 AS-12-4 OP4-WC05 3 IS MS-15-4 AS Stock Availability. Stocked Stocked in limited quantities Non-Stocked Standard (6 week lead time) 7
10 BT40/BT50 Flange, Coating and Availability - 10 Piece Packs Grade AM200 TiN TiAN TiCN Z55 OP-05T308-H OP-05T308-T OP-05T308-A OP-05T308-N BT40 () BT40 OP1-1S-BT40 OP1 BT40 Short OP1-1L-BT40 OP1 BT40 Long OP2-1S-BT40 OP2 BT40 Short OP2-1L-BT40 OP2 BT40 Long OP3-1S-BT40 OP3 BT40 Short OP3-1L-BT40 OP3 BT40 Long OP4-1S-BT40 OP4 BT40 Short BT50 () BT50 OP1-1S-BT50 OP1 BT50 Short OP1-1L-BT50 OP1 BT50 Long OP2-1S-BT50 OP2 BT50 Short OP2-1L-BT50 OP2 BT50 Long OP3-1S-BT50 OP3 BT50 Short OP3-1L-BT50 OP3 BT50 Long OP4-1S-BT50 OP4 BT50 Short OP4-1L-BT50 OP4 BT50 Long Replacement Cartridges Qty Inserts Required Insert 10 Pack Mounting Adjusting OP1-WC05 2 IS MS-13-4 AS-10-4 OP2-WC05 2 IS MS-15-4 AS-10-4 OP3-WC05 2 IS MS-15-4 AS-12-4 OP4-WC05 3 IS MS-15-4 AS Stock Availability. Stocked Stocked in limited quantities Non-Stocked Standard (6 week lead time) 8
11 HSK63A/C & HSK100A/C, Coating and Availability - 10 Piece Packs Grade AM200 TiN TiAN TiCN Z55 OP-05T308-H OP-05T308-T OP-05T308-A OP-05T308-N HSK 63A/C () HSK63A/C OP1-1S-HSK63 OP1 HSK63A/C Short OP1-1L-HSK63 OP1 HSK63A/C Long OP2-1S-HSK63 OP2 HSK63A/C Short OP2-1L-HSK63 OP2 HSK63A/C Long OP3-1S-HSK63 OP3 HSK63A/C Short OP3-1L-HSK63 OP3 HSK63A/C Long OP4-1S-HSK63 OP4 HSK63A/C Short HSK 100A/C () HSK 100A/C OP1-1S-HSK100 OP1 HSK100A/C Short OP1-1L-HSK100 OP1 HSK100A/C Long OP2-1S-HSK100 OP2 HSK100A/C Short OP2-1L-HSK100 OP2 HSK100A/C Long OP3-1S-HSK100 OP3 HSK100A/C Short OP3-1L-HSK100 OP3 HSK100A/C Long OP4-1S-HSK100 OP4 HSK100A/C Short OP4-1L-HSK100 OP4 HSK100A/C Long Replacement Cartridges Qty Inserts Required Insert 10 Pack Mounting Adjusting OP1-WC05 2 IS MS-13-4 AS-10-4 OP2-WC05 2 IS MS-15-4 AS-10-4 OP3-WC05 2 IS MS-15-4 AS-12-4 OP4-WC05 3 IS MS-15-4 AS Stock Availability. Stocked Stocked in limited quantities Non-Stocked Standard (6 week lead time) 9
12 Operation The has 2 diametrically opposed cartridges that are phased to create an overlapping cut situation in use. The cartridges are exactly the same until one is selected to cut the finish diameter, outer cartridge. The other opposing cartridge would then become the inner cartridge. The inner cartridge would be adjusted to a smaller radius by a range of 4.06mm mm. The phasing on the inner cartridge does not require close accuracy but using the mean size of 4.57mm is recommended. Outer Arm Inner Arm Set Up Procedure The must be presented close to centre line. A stationary AMEC Core Drill must be on centre line with the part within 0.381mm total runout. AMEC strongly suggests that the turret pod be indicated from the chuck before tool mounting. Applications on a machining centre will typically find their own centre, but we recommend TIR to be within 0.127mm. We recommend utilising coolant when using the. Through the tool is ideal, although flood coolant is acceptable. The tool is designed with large gullets to easily evacuate the chips from the hole. The can be effectively used to core holes with 2 inserts, if both opposed cartridges are set to the same cut diameter. However, this application will not allow an enlargement greater than 12.7mm on diameter. Presetter: In setting the the use of a presetter will allow for the most accurate setting of the tool. Set the presetter axis to diameter. Designate one of the cartridges to be the outer cartridge (finish diameter), the opposing cartridge then becomes the inner cartridge. Set the outer cartridge to the finish diameter required. We recommend adjusting the cartridge using the side adjusting screws that push against the pin. After this initial adjustment is made, tighten the mounting screws to secure the cartridges and then slightly tension the adjusting screws to insure a friction fit in the screw threads. The inner cartridge is then adjusted to a smaller diameter within a range of 8.13mm mm. The nominal Ø value of 9.14mm is recommended. However, anything within the range is acceptable, for the inner cartridge does not require a close accuracy. Dial Test Indicator (DTI): In the case that a presetter is unavailable the setting of the tool can be set accurately as follows: Diameter OP OP OP OP Figure 1 Figure 2 Figure 3 Figure 4 1) Outer Cartridge Setting Finish Ø Minus Ø (Figure 1) /2 = Distance indicator will need to travel from tool body (Figure 2) to set outer cartridge at finish diameter (Figure 3) 2) Inner Cartridge Setting 4.57 mean on radius (Range 4.06mm mm) 9.14mm mean on dia (Range 8.13mm mm) Offset the inner cartridge inwards by Ø 9.14/2 = Distance indicator will need to travel from outer cartridge to set inner cartridge (Figure 4) ensuring optimum insert overlap. 10
13 Recommended Speeds and Feeds Material Material Hardness (BHN) Speed M/min AM200 TiN TiAlN TiCN Feed (mm/rev) Free Machining Steel Low Carbon Steel Medium Carbon Steel Alloy Steel High Strength Alloy Structural Steel High Temperature Alloy Hastelloy B, Inconel 600 Stainless Steel Tool Steel Aluminium Cast Iron Grey, Ductile, Nodular Brass Formulas: mm/min = RPM mm/rev M/min = RPM DIA RPM = M/min /DIA The speeds recommended for all coated tools are based on empirical data obtained under Optimum Conditions. Many applications do not exhibit Optimum Conditions. (Reductions in speed parameters may be required due to excessive tool wear generated in the application.) The speeds and feeds listed above are considered a general starting point for all applications. Factory technical assistance is also available for your specific applications through our Application Engineering Team. Please have item number, hole diameter, depth, material grade, BHN hardness and coolant pressure information available when you call. Additional information such as part and machine rigidity, horsepower and thrust limits, vertical or horizontal spindle, revolving or stationary tool, flood or through holder coolant will enable our Application Engineers to give you the best possible solution. Minimum Pilot Hole Calculation To determine the minimum diameter of the pilot hole, use the following calculation: FINISH DIAMETER MINUS OPENING RANGE = MINIMUM PILOT HOLE DIAMETER For example: To open up an existing diameter hole to 66mm diameter, OP2 tool would be used and the minimum pilot hole diameter would be 66mm-47.75mm = 18.25mm. Pre-drilled part or core AMEC Core Adjustable O.D Opening Range Drill Size Range Diameter OP OP OP OP
14 AMEC Request for Guaranteed Application Trial P.O No... Date... Proposed Test Date... Distributor... Customer Name... Distributor Contact... Contact Name... APPLICATION INFORMATION ATTENTION: The following information is required to enable the best combination of tooling to be recommended. Please check all that apply Material Type... Specification... Material Hardness... BHN RC Material Condition Flat Stock Round Stock Tubular Stock Plate Stacked Plate Hot Rolled Cold Rolled Casting Forging Current Hole Diameter... mm Inch Hole... Thru Hole Blind Hol Cored Hole Size... Drilled Hole Tolerance Req d... Drilled Hole RMS Finish Req d... Micro-Inch Micro-Metre MACHINE AND SET-UP INFORMATION Machine Tool Type Machining Centre Lathe Boring Mill Transfer Line Machine Multi-Spindle Drill Radial Arm Drill Gantry Machine Dial Index Machine Pedestal Drill Gun Drilling Machine Other Machine Tool Builder... Model... Machine Tool Control CNC NC Manual Other... Spindle Orientation Vertical Horizontal Other... Tool Stationery Revolves Available Power... KW HP Available Feed Thrust... Newtons Lbs Available Speed Variable Fixed RPM M/min Preferred Type mm Inch Coolant Type Cutting Oil Water Soluble Oil Air Mist Air Dry Coolant Pressure Bar PSI Coolant Flow Rate... L/min GPM Coolant Application Through Tool Flood CURRENT DRILL INFORMATION Drill Manufacturer... Part... Drill Type... Indexable Insert Gun Drill. Tool Grade HSS Carbide Ceramic Other... Tool Coating Uncoated TiN TiCN TiAlN Other... Current Speed... RPM M/min Current Feed Rate... mm/rev mm/min Average of Holes Drilled... Reason(s) for Tool Change Wear Chipping Fracture Chatter Performance Losing Hole Tolerance Other... What criteria defines a Successful test... Potential this application: Current Annual Usage / : Tools per Annum? 12
15 European Headquarters: Allied Maxcut Engineering Co. Limited 93 Vantage Point, Pensnett Estate, Kingswinford, West Midlands, DY6 7FR England Tel: +44 (0) Fax: +44 (0) Website: AM-CAT-COREV(GB)-11/08
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