DRV Magic Drill. High Efficiency Indexable Drill. Economical Inserts with 4 Cutting Edges and Excellent Chip Evacuation

Transcription

1 DRV Magic Drill High Efficiency Indexable Drill Economical Inserts with 4 Cutting Edges and Excellent Chip Evacuation xd to 6xD drilling lineup with 4 chipbreakers for various machining applications High speed and highly efficient machining with the combination of a CVD outer insert and PVD inner insert Excellent hole accuracy with a highly rigid design for better chatter resistance

2 DRV Magic Drill High Efficiency Indexable Drill Product Video Economical Inserts with 4 Cutting Edges Excellent Chip Evacuation with 6D Maximum Deep-Hole Drilling High Speed and Highly Efficient Machining with the Combination of CVD (Outer Edge) and PVD () Inserts 1 Excellent Drilling Precision with Less Variation in Cutting Diameter Optimal Web Thickness and Low Cutting Force Design Reduces Chattering Web Thickness Comparison Cutting Diameter Variation Comparison Cutting Force Comparison (Internal Evaluation) (Internal Evaluation) (Internal Evaluation) 33% Larger DRV Competitor Cutting Diameter Variation (in) DRV Competitor B Thrust Force (N) 3,,5, 1,5 1, 5 39% 1,474, Drilling Depth (in) DRV Competitor C Cutting Conditions : Vc = 49 sfm, f =.4 ipr Cutting Dia. Ø.81" (5D), Wet, Workpiece : 149 Cutting Conditions : Vc = 66 sfm, f =.47 ipr Cutting Dia. Ø.81" (3D), Wet, Workpiece : 149 Unique Insert Design to Control Chip Flow Outer Edge Insert Unique Insert Pattern to Differentiate between Outside and Inside Inserts U-shaped Cutting Edge Insert Smooth Chip Evacuation with Compact Chips Chip Shape Comparison of Outer Insert Cutting Edge (Internal Evaluation) DRV :.394" Competitor D :.47" 16% Smaller Chips Cutting Conditions : Vc = 49 sfm, f =.4 ipr, Cutting Dia. Ø.81 (3D), Wet Workpiece : 149 Excellent Chip Evacuation with 6xD Maximum Deep-Hole Drilling Weight per Unit of Length for Chips Generated by the Inner Insert (Internal Evaluation) DRV 8mg/mm 47% Spoon-shaped Cutting Edge Competitor E 151mg/mm DRV : 1.mm Cutting Conditions : Vc = 8 sfm, f =.31 ipr, Cutting Dia. Ø.81 (5D), Wet, Workpiece : 34 Competitor E :.5mm Lighter Chips

3 3 New Insert Grades Developed for Drilling High Speed and Highly Efficient Machining with the Combination of CVD (Outer Edge) and PVD () Inserts : PVD (PR1535) Outer Edge : CVD (C5D / C415D) Recommended Cutting Conditions (Maximum Values) Wear Resistance Comparison (Internal Evaluation) Vc (sfm) % 9 59 Wear (in) DRV (C5D) Competitor F (CVD) Competitor G (CVD) CVD (C5D) PVD (PR15) Cutting Time (min) Cutting Dia. Ø.81" (3D) Workpiece : 149 See Page 19 for Insert Grade Selection Guide Cutting Conditions : Vc = 66 sfm, f =.47 ipr, Cutting Dia. Ø.81" (3D), Wet Workpiece : 414H 4 Economical 4-Edge Inserts 4 Types of Chipbreakers for Various Machining pplications GM Chipbreaker - General Purpose Chipbreaker for Machining Stable Deep-hole Machining with Low Cutting Force GH Chipbreaker - Tough Edge 1st Recommendation for Machining Cast Iron Good for Interrupted Machining Reduces Insert Chipping Common in Through-hole Machining - Section Edge shape optimized for various machining applications B B B-B Section Negative land with strong edge SM Chipbreaker - For Stainless Machining Stable Chip Control when Machining Gummy Stainless Reduces Chip Clogging in the Holder Body Chip Control Comparison (Internal Evaluation) Outer Edge Comparison of Remaining Chips (Internal Evaluation) DRV (SM Chipbreaker) C C C-C Section Sharp cutting and large rake angle Inner Edge DRV (SM Chipbreaker) Competitor H Competitor I Remaining Chips Cutting Conditions : Vc = 33 sfm, f =.39 ipr Cutting Dia. Ø.81" (3D), Drilling Depth.436" Wet, Workpiece : 34 Cutting Conditions : Vc = 49 sfm, f =.31 ipr Cutting Dia. Ø.984" (5D), Drilling Depth 3.858" Wet, Workpiece : 34 XM Chipbreaker - For Machining Soft and SS Material Stable Chip Control of Outer Cutting Edge Chip Control Comparison (Internal Evaluation) Outer Edge D D E E Excellent chip control with the changing width of the chipbreaker Inner Edge D-D Section E-E Section DRV (XM Chipbreaker) Cutting Conditions : Vc = 66 sfm, f =.47 ipr Cutting Dia. Ø.65" (3D), Drilling Depth 1.875" Wet, Workpiece : 36 Competitor J Chipbreaker Selection Chart P4 3

4 Case Studies Case Studies Housing - Structural Nipple - Stainless Vc = 41 sfm (n = 1,66 rpm) f =.3 ipr (Vf = 5.36 ipm) Drilling Depth 1.77" Wet (External Coolant) S1-DRV SCMT731GM-I PR1535 SCMT735GM-E PR15 Vc = 76 sfm (n = 3,33 rpm) f =.5 ipr (Vf = ipm) Drilling Depth.36" (4xD) 1.181" (xd) Wet (Internal Coolant) S1-DRV (4xD) S1-DRV (xd) SCMT61-GM-I PR1535 SCMT65-GM-E PR15 Process Drilling Depth (xd) Process 1 Drilling Depth.36 (4xD) Cutting Time DRV (Ø.938 4xD) Competitor K (Ø.938 4xD) 16 sec 35 sec 5% or More Cutting Time Cutting Time DRV (Ø.938 4xD/xD) Competitor L (Ø.875 4xD/xD) 1 sec sec 4% Cutting Time Chattering and recutting chips occurred in low rigidity workpiece of Competitor K. Speed was reduced to Vc = sfm. DRV provided good chip control for stable machining at Vc = 41 sfm. (User Evaluation) Chattering and deflection occurred with Competitor L. DRV showed stable machining and a shorter cutting time even when the cutting conditions were increased by 1.6 times or more. (User Evaluation) Chipbreaker Selection Chart P (Carbon / lloy ) M (Stainless ) K (Cast Iron) Low Carbon Material where Chips are Easily Elongated Medium to High Carbon Non Heat-Treated Materials Fracture Resistance or Heat-Treated Material Low Cutting Resistance Fracture Resistance No Interruption Interrupted Low Cutting Resistance XM Chipbreaker For Soft SM Chipbreaker Low Resistance GM Chipbreaker General Purpose GH Chipbreaker Tough Edge SM Chipbreaker Low Resistance GM Chipbreaker General Purpose GH Chipbreaker Tough Edge Prevent Recutting Chips Fracture Resistance XM Chipbreaker For Soft GH Chipbreaker Tough Edge 4

5 DRV Toolholders - Inch Sizes L 1 Toolholder Dimension D (Drilling Depth : ) Stock No. of Inserts Dimension (in) Max. Radial Spare Parts Offset L 1 (in) Clamp Screw Wrench pplicable Insert See Page 13 S75- DRV DRV S1- DRV SB-41TRP Outer Edge SCMT55E SCMT51I DRV DRV DRV SB-555TRP DTPM-8 Outer Edge SCMT65E SCMT61I DRV DRV DRV SB-36TRP Outer Edge SCMT735E SCMT731I : U.S. Stock L 1 Toolholder Dimension 3D (Drilling Depth : 3 ) Stock No. of Inserts Dimension (in) Max. Radial Spare Parts Offset L 1 (in) Clamp Screw Wrench pplicable Insert See Page 13 S75- DRV DRV S1- DRV SB-41TRP Outer Edge SCMT55E SCMT51I DRV DRV DRV SB-555TRP DTPM-8 Outer Edge SCMT65E SCMT61I DRV DRV DRV SB-36TRP Outer Edge SCMT735E SCMT731I Estimated Cutting Tolerance (D & 3D) : U.S. Stock Estimated Cutting Tolerance (in) Ø.65" - Ø1." +.1 The above values are estimates. These values may change due to machine, workpiece, clamping power, and cutting conditions Recommended Cutting Conditions P14~P15 djustable Sleeve SL P16 5

6 DRV Toolholders - Inch Sizes L 1 Toolholder Dimension 4D (Drilling Depth : 4 ) Stock No. of Inserts Dimension (in) Max. Radial Spare Parts Offset L 1 (in) Clamp Screw Wrench pplicable Insert See Page 13 S75- DRV DRV S1- DRV SB-41TRP Outer Edge SCMT55E SCMT51I DRV DRV DRV SB-555TRP DTPM-8 Outer Edge SCMT65E SCMT61I DRV DRV DRV SB-36TRP Outer Edge SCMT735E SCMT731I : U.S. Stock L 1 Toolholder Dimension 5D (Drilling Depth : 5 ) Stock No. of Inserts Dimension (in) Max. Radial Spare Parts Offset L 1 (in) Clamp Screw Wrench pplicable Insert See Page 13 S75- DRV DRV S1- DRV SB-41TRP Outer Edge SCMT55E SCMT51I DRV DRV DRV SB-555TRP DTPM-8 Outer Edge SCMT65E SCMT61I DRV DRV DRV SB-36TRP Outer Edge SCMT735E SCMT731I Estimated Cutting Tolerance (4D & 5D) : U.S. Stock Ø.65" - Ø1." Estimated Cutting Tolerance (in) +.14 The above values are estimates. These values may change due to machine, workpiece, clamping power, and cutting conditions Recommended Cutting Conditions P14~P15 djustable Sleeve SL P16 6

7 DRV Toolholders - Inch Sizes L 1 Toolholder Dimension 6D (Drilling Depth : 6 ) Stock No. of Inserts Dimension (in) Max. Radial Spare Parts Offset L 1 (in) Clamp Screw Wrench pplicable Insert See Page 13 S75- DRV DRV S1- DRV SB-41TRP Outer Edge SCMT55E SCMT51I DRV DRV DRV SB-555TRP DTPM-8 Outer Edge SCMT65E SCMT61I DRV DRV DRV SB-36TRP Outer Edge SCMT735E SCMT731I Estimated Cutting Tolerance (6D) : U.S. Stock Ø.65" - Ø1." Estimated Cutting Tolerance (in) +.18 The above values are estimates. These values may change due to machine, workpiece, clamping power, and cutting conditions Recommended Cutting Conditions P14~P15 djustable Sleeve SL P16 DRV Magic Drill Current Lineup and Future Expansion Metric Sizes DRV Ø14mm~Ø3mm D~6D Inch Sizes DRV vailable Ø.65 ~Ø1. D~6D DRV Future Expansion Ø.5 ~Ø. D~6D Ø.5 Ø.65 Ø1. Ø. Drill Diameter (in) 7

8 DRV Toolholders - Metric Sizes L 1 Toolholder Dimension D (Drilling Depth : ) Stock No. of Inserts Dimension (mm) Max. Radial Spare Parts Offset L 1 (mm) Clamp Screw Wrench pplicable Insert See Page 13 S- DRV14M--4 ß DRV145M--4 ß DRV15M--4 ß SB-37TRP Outer Edge SCMT45E SCMT49I DRV155M--4 ß S5- DRV16M--5 ß DRV165M--5 ß DRV17M--5 ß DRV175M--5 ß SB-41TRP Outer Edge SCMT55E SCMT51I DRV18M--5 ß DRV185M--5 ß S5- DRV19M--6 ß DRV195M--6 ß DRVM--6 ß DRV5M--6 ß DRV1M--6 ß SB-555TRP DTPM-8 Outer Edge SCMT65E SCMT61I DRV15M--6 ß DRVM--6 ß S5- DRV5M--7 ß DRV3M--7 ß DRV35M--7 ß DRV4M--7 ß DRV45M--7 ß SB-36TRP Outer Edge SCMT735E SCMT731I DRV5M--7 ß DRV55M--7 ß DRV6M--7 ß S3- DRV7M--9 ß DRV8M--9 ß DRV9M--9 ß DRV3M--9 ß SB-3573TRP Outer Edge SCMT945E SCMT941I DRV31M--9 ß DRV3M--9 ß ß : World Express (Shipping: 7-1 Business Days) Estimated Cutting Tolerance (D) Ø14mm - Ø3mm Estimated Cutting Tolerance (mm) +.3 The above values are estimates. These values may change due to machine, workpiece, clamping power, and cutting conditions Recommended Cutting Conditions P14~P15 djustable Sleeve SHE P16 8

9 DRV Toolholders - Metric Sizes L 1 Toolholder Dimension 3D (Drilling Depth : 3 ) Stock No. of Inserts Dimension (mm) Max. Radial Spare Parts Offset L 1 (mm) Clamp Screw Wrench pplicable Insert See Page 13 S- DRV14M-3-4 ß DRV145M-3-4 ß DRV15M-3-4 ß Estimated Cutting Tolerance (3D) DRV155M-3-4 ß S5- DRV16M-3-5 ß DRV165M-3-5 ß DRV17M-3-5 ß DRV175M-3-5 ß DRV18M-3-5 ß DRV185M-3-5 ß S5- DRV19M-3-6 ß DRV195M-3-6 ß DRVM-3-6 ß DRV5M-3-6 ß DRV1M-3-6 ß DRV15M-3-6 ß DRVM-3-6 ß S5- DRV5M-3-7 ß DRV3M-3-7 ß DRV35M-3-7 ß DRV4M-3-7 ß DRV45M-3-7 ß DRV5M-3-7 ß DRV55M-3-7 ß DRV6M-3-7 ß S3- DRV65M-3-9 ß DRV7M-3-9 ß DRV75M-3-9 ß DRV8M-3-9 ß DRV85M-3-9 ß DRV9M-3-9 ß DRV95M-3-9 ß DRV3M-3-9 ß DRV35M-3-9 ß DRV31M-3-9 ß DRV315M-3-9 ß DRV3M-3-9 ß Ø14mm - Ø3mm Estimated Cutting Tolerance (mm) +.3 The above values are estimates. These values may change due to machine, workpiece, clamping power, and cutting conditions SB-37TRP SB-41TRP SB-555TRP SB-36TRP SB-3573TRP Outer Edge SCMT45E SCMT49I Outer Edge SCMT55E SCMT51I DTPM-8 Outer Edge SCMT65E SCMT61I Outer Edge SCMT735E SCMT731I Outer Edge SCMT945E SCMT941I ß : World Express (Shipping: 7-1 Business Days) Recommended Cutting Conditions P14~P15 djustable Sleeve SHE P16 9

10 DRV Toolholders - Metric Sizes L 1 Toolholder Dimension 4D (Drilling Depth : 4 ) Stock No. of Inserts Dimension (mm) Max. Radial Spare Parts Offset L 1 (mm) Clamp Screw Wrench pplicable Insert See Page 13 S- DRV14M-4-4 ß DRV145M-4-4 ß DRV15M-4-4 ß SB-37TRP Outer Edge SCMT45E SCMT49I DRV155M-4-4 ß S5- DRV16M-4-5 ß DRV165M-4-5 ß DRV17M-4-5 ß DRV175M-4-5 ß SB-41TRP Outer Edge SCMT55E SCMT51I DRV18M-4-5 ß DRV185M-4-5 ß S5- DRV19M-4-6 ß DRV195M-4-6 ß DRVM-4-6 ß DRV5M-4-6 ß DRV1M-4-6 ß SB-555TRP DTPM-8 Outer Edge SCMT65E SCMT61I DRV15M-4-6 ß DRVM-4-6 ß S5- DRV5M-4-7 ß DRV3M-4-7 ß DRV35M-4-7 ß DRV4M-4-7 ß DRV45M-4-7 ß SB-36TRP Outer Edge SCMT735E SCMT731I DRV5M-4-7 ß DRV55M-4-7 ß DRV6M-4-7 ß S3- DRV7M-4-9 ß DRV8M-4-9 ß DRV9M-4-9 ß DRV3M-4-9 ß SB-3573TRP Outer Edge SCMT945E SCMT941I DRV31M-4-9 ß DRV3M-4-9 ß ß : World Express (Shipping: 7-1 Business Days) Estimated Cutting Tolerance (4D) Ø14mm - Ø3mm Estimated Cutting Tolerance (mm) +.35 The above values are estimates. These values may change due to machine, workpiece, clamping power, and cutting conditions Recommended Cutting Conditions P14~P15 djustable Sleeve SHE P16 1

11 DRV Toolholders - Metric Sizes L 1 Toolholder Dimension 5D (Drilling Depth : 5 ) Stock No. of Inserts Dimension (mm) Max. Radial Spare Parts Offset L 1 (mm) Clamp Screw Wrench pplicable Insert See Page 13 S- DRV14M-5-4 ß DRV15M ß S5- DRV16M-5-5 ß DRV17M-5-5 ß DRV18M-5-5 ß S5- DRV19M-5-6 ß DRVM-5-6 ß DRV1M ß DRVM-5-6 ß S5- DRV3M-5-7 ß DRV4M-5-7 ß DRV5M ß DRV6M-5-7 ß S3- DRV7M-5-9 ß DRV8M-5-9 ß DRV9M-5-9 ß DRV3M ß DRV31M-5-9 ß DRV3M-5-9 ß Estimated Cutting Tolerance (5D) SB-37TRP SB-41TRP SB-555TRP SB-36TRP SB-3573TRP Outer Edge SCMT45E SCMT49I Outer Edge SCMT55E SCMT51I DTPM-8 Outer Edge SCMT65E SCMT61I Outer Edge SCMT735E SCMT731I Outer Edge SCMT945E SCMT941I ß : World Express (Shipping: 7-1 Business Days) Estimated Cutting Tolerance (mm) Ø14mm - Ø3mm +.35 The above values are estimates. These values may change due to machine, workpiece, clamping power, and cutting conditions Recommended Cutting Conditions P14~P15 djustable Sleeve SHE P16 11

12 DRV Toolholders - Metric Sizes L 1 Toolholder Dimension 6D (Drilling Depth : 6 ) Stock No. of Inserts Dimension (mm) Max. Radial Spare Parts Offset L 1 (mm) Clamp Screw Wrench pplicable Insert See Page 13 S- DRV14M-6-4 ß DRV15M ß S5- DRV16M-6-5 ß DRV17M-6-5 ß DRV18M-6-5 ß S5- DRV19M-6-6 ß DRVM-6-6 ß DRV1M ß DRVM-6-6 ß S5- DRV3M-6-7 ß DRV4M-6-7 ß DRV5M ß DRV6M-6-7 ß S3- DRV7M-6-9 ß DRV8M-6-9 ß DRV9M-6-9 ß DRV3M ß DRV31M-6-9 ß DRV3M-6-9 ß Estimated Cutting Tolerance (6D) SB-37TRP SB-41TRP SB-555TRP SB-36TRP SB-3573TRP Outer Edge SCMT45E SCMT49I Outer Edge SCMT55E SCMT51I DTPM-8 Outer Edge SCMT65E SCMT61I Outer Edge SCMT735E SCMT731I Outer Edge SCMT945E SCMT941I ß : World Express (Shipping: 7-1 Business Days) Estimated Cutting Tolerance (mm) Ø14mm - Ø3mm +.45 The above values are estimates. These values may change due to machine, workpiece, clamping power, and cutting conditions Recommended Cutting Conditions P14~P15 djustable Sleeve SHE P16 1

13 pplicable Inserts Usage Classification P : 1st Recommendation (High Speed and Highly Efficient Machining) : nd Recommendation (Stable Machining Oriented) Insert Pocket Insert T α rε General Purpose T α rε Tough Edge Outer Edge T Soft Machining α rε T α rε Stainless Machining T α rε General Purpose T Tough Edge α rε Inner Edge T Soft Machining α rε rε Stainless Machining -E : Outer Edge Insert -I : Insert T α Carbon / lloy Tool M Stainless K Cast Iron Dimensions (in) ngle MEGCOT CVD Coated Carbide α PR15 C5D C415D MEGCOT NNO PR1535 T rε SCMT 45-GM-E GM-E GM-E GM-E GM-E SCMT 55-GH-E GH-E GH-E SCMT 55-XM-E XM-E XM-E SCMT 45-SM-E SM-E SM-E SM-E SM-E SCMT 49-GM-I GM-I GM-I GM-I GM-I SCMT 51-GH-I GH-I GH-I SCMT 51-XM-I XM-I XM-I SCMT 49-SM-I SM-I SM-I SM-I SM-I Recommended Cutting Conditions P14~P15 Inserts are sold in 1 piece boxes 13

14 Recommended Cutting Conditions 1st Recommendation nd Recommendation DRV - Recommended Cutting Conditions (with Coolant) Workpiece Material Low Carbon Carbon lloy Tool Stainless (ustenitic) Gray Cast Iron Nodular Cast Iron Workpiece Material Low Carbon Carbon lloy Tool Stainless (ustenitic) Gray Cast Iron Nodular Cast Iron Drilling Depth: D~4D Recommended Insert Grade / Cutting Speed (sfm) Inch Metric Drill Depth / Feed Rate (ipr) PVD Coated Carbide CVD Coated Carbide Drill Dia. Drill Dia. PR15 C5D C415D D~3D (in) (mm) GM GH XM SM GM GH XM SM GM GH GM GH XM SM ~ ~.39.4 ~ ~.47.4 ~ ~.55.4 ~ ~ Internal Coolant is Recommended ~ ~ ~.63.4 ~.63.4 ~.47.4 ~ ~ ~.79.4 ~.55.4 ~ ~.79.4 ~ ~ ~.63.4 ~ ~ ~ ~ ~ ~.47.4 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~.71 - Recommended Insert Grade / Cutting Speed (sfm) Inch Metric Drill Depth / Feed Rate (ipr) PVD Coated Carbide CVD Coated Carbide Drill Dia. Drill Dia. PR15 C5D C415D 4D (in) (mm) GM GH XM SM GM GH XM SM GM GH GM GH XM SM ~ ~.31. ~ ~.39. ~ ~.47. ~ ~ ~ ~ ~.47. ~.47. ~.39. ~ ~.63.8 ~.63. ~.47. ~ ~.63. ~ ~ ~.47. ~ ~.63.8 ~ ~ ~ ~.39.4 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~.63 - Cutting Conditions by pplication pplications Plain Surface ngled Surface Half Cylindrical Hole Expansion Existing Hole Concave Surface Stacked Plates Workpiece Shape Cutting Speed Vc (sfm) f (ipr) See recommended cutting conditions above See recommended cutting conditions above 39 (PVD insert is recommended for outer edge) Not Recommended 5% of above recommendation 5% of above recommendation initially. See recommendations above once drill is fully engaged. Not vailable Internal Coolant Yes Not Recommended 14

15 Recommended Cutting Conditions 1st Recommendation nd Recommendation DRV - Recommended Cutting Conditions (with Coolant) Workpiece Material Low Carbon Carbon lloy Tool Stainless (ustenitic) Gray Cast Iron Nodular Cast Iron Workpiece Material Low Carbon Carbon lloy Tool Stainless (ustenitic) Gray Cast Iron Nodular Cast Iron Drilling Depth: 5D~6D Recommended Insert Grade / Cutting Speed (sfm) Inch Metric Drill Depth / Feed Rate (ipr) PVD Coated Carbide CVD Coated Carbide Drill Dia. Drill Dia. PR15 C5D C415D 5D (in) (mm) GM GH XM SM GM GH XM SM GM GH GM GH XM SM ~ ~ ~ ~ ~ ~ ~ ~ Internal Coolant is Recommended ~ ~ ~.39. ~.39. ~.31. ~ ~.47.4 ~.47. ~.39. ~ ~.47. ~ ~ ~.39. ~ ~.47.4 ~ ~ ~ ~ ~ ~.39. ~ ~ ~ ~ ~ ~ ~ ~.47.4 ~ ~.55.4 ~ ~ ~ ~.39.4 ~ ~.47.4 ~ ~.47 - Recommended Insert Grade / Cutting Speed (sfm) Inch Metric Drill Depth / Feed Rate (ipr) PVD Coated Carbide CVD Coated Carbide Drill Dia. Drill Dia. PR15 C5D C415D 6D (in) (mm) GM GH XM SM GM GH XM SM GM GH GM GH XM SM ~ ~.4.16 ~ ~.8.16 ~ ~ ~ ~ ~.4.16 ~ ~.31. ~.31. ~.8. ~ ~.39.4 ~.39. ~.31. ~ ~.39. ~ ~ ~.31. ~ ~.39.4 ~ ~ ~ ~.4.16 ~ ~.31. ~ ~ ~ ~ ~ ~ ~ ~.39.4 ~ ~.47.4 ~ ~ ~ ~.31.4 ~ ~.39.4 ~ ~.39 - Cutting Conditions by pplication pplications Plain Surface ngled Surface Half Cylindrical Hole Expansion Existing Hole Concave Surface Stacked Plates Workpiece Shape Cutting Speed Vc (sfm) f (ipr) See recommended cutting conditions above See recommended cutting conditions above 39 (PVD insert is recommended for outer edge) Not Recommended 5% of above recommendation 5% of above recommendation initially. See recommendations above once drill is fully engaged. Not vailable Internal Coolant Yes Not Recommended 15

16 djustable Sleeve (Cutting Diameter & Center Height djustment) ØD ØD1 L L4 Sleeve Dimensions (Use SL for Inch Size Drills and SHE for Metric Size Drills) Stock Unit Dimension ØD1 ØD L L4 Diameter djustment Range Center Height djustment Range SL ~ ~ inch ~ ~ ~ ~ -.6 SHE 5-43 ß ~ ~ ß ~ ~ -.15 mm ß ~ ~ ß ~ ~ -. Diameter adjustment range refers to the cutting diameter. SL and SHE sleeves can also be used with the DRX and DRZ Magic Drills : U.S. Stock ß : World Express (Shipping: 7-1 Business Days) 1 Diameter djustment For Machining Center Center Height djustment For Lathe Operations Example: Ø3mm Drill Small Large Ø9.8mm Ø3.4mm Diameter djustment Shank Dia. Ø.75" Ø1." Ø1.5" SL (in) djustment Range +.16 ~ -.8 Shank Dia. Ø Ø5 Ø3 SHE (mm) djustment Range +.4 ~ -. - Ø4 +.6 ~ -. Center Height djustment Shank Dia. Ø.75" Ø1." Ø1.5" SL (in) djustment Range +.8 ~ -.6 Shank Dia. Ø Ø5 Ø3 SHE (mm) djustment Range +. ~ Ø4 +.3 ~ -. How to Use the djustable Sleeve 1 Hole Diameter djustment when Drilling 1. lign the scale at the flange periphery of the sleeve to the center of the coolant plug of the drill. (Fig.1). When making the hole diameter bigger, rotate the sleeve in the (+) direction and to make it smaller, rotate the sleeve in the (-) direction. 3. When rotating the sleeve, insert the wrench supplied with the drill into the hole on the flange periphery to rotate the sleeve. 4. Using the bottom screw of the side-lock arbor, firmly tighten the drill directly through the sleeve's window. The upper screw should be tightened slightly so that the sleeve will not be damaged. (Caution) Not for use with collet chuck type arbor. Check the actual cutting diameter after adjusting. Bottom Screw (Tighten Firmly) Top Screw (Tighten Slightly) Center-Height djustment for Lathes Fig.1 Reference Mark Fig. Most of the problems encountered with a turning lathe are center-height deviations. The center height is appropriate if a core of about.5mm (.") diameter remains at the center of the hole. Center-height adjustment is necessary when no core remains or if the core diameter is more than 1mm ("). 1. lign the drill with the outer insert face parallel to the tool turret. (Fig.4). lign the scale (for the lathe) on the flange face of the sleeve to the center of the reference mark. 3. When no core remains, rotate the sleeve in the (+) direction to make the core larger, and when the core diameter is more than 1mm, rotate the sleeve in the (-) direction to make the core smaller. 4. When rotating the sleeve, insert the wrench supplied with the drill into the hole of the flange and then rotate the sleeve. 5. fter Completing the adjustment, tighten the drill directly through the window on the sleeve. Fig.3 Core Flat Surface Fig.4 Flange (Caution) Depending on amount of the center height adjustment, the hole diameter may change. It is recommended that the hole diameter is checked after the center height adjustment. 16

17 Lathe Installation 1. The top face of the outer insert should be parallel to the X-axis to allow for offset cutting. (Cutting diameter can be changed by moving in the X-axis.). It is recommended to set the outer insert as shown in Fig.1 with the outer insert facing the operator. (Fig.1) (It is also possible to use it by setting it in 18 reverse position) If the lathe has two turrets, when installing the drill into the lower turret, the outer insert should be set to face the operator. (It is also possible to use it by setting at 18 reverse position) Moving Direction of X-axis Turret Flat Surface Flange Outer Edge Fig.1 Installed into the Lathe Cutting Diameter djustment 1 Cutting Diameter djustment Smaller 1. Cutting diameter is adjusted by moving X-axis. The moving direction of the X-axis depends on the position of the toolholder.. For making the hole diameter larger, slide the tool along the X-axis toward the outer insert side. (Fig., Fig.3) For making the hole diameter smaller, slide the tool along the X-axis in the opposite direction. (This movement of the axis is called an Offset ) Be sure not to make the hole diameter smaller than the drill diameter by more than.mm (.8"). Otherwise, the toolholder will interfere with the drilled hole. (Fig.4) Ex.) When using Ømm drill, the hole diameter must not be smaller than 19.8m (.78") Flat Surface Fig. Outer Insert Facing Up Larger Flange Outer Edge Outer Edge Larger Flat Surface Smaller Flange Offset Limit of the Cutting Diameter For the maximum limit of the cutting diameter, refer to Max. Offset (Radial) in the Toolholder Dimensions table. (The figure in the Toolholder Dimensions table shows how much it is possible to offset the drill in the radial direction.) Ex.) When using Ømm (Ø.787") drill, for example, it is possible to make a hole up to Ø1.1mm (.831") since "Max. Offset (Radial)" is +.55mm (+."). Interference Flat Surface Center of Drill Fig.3 Outer Insert Facing Down Cutting Dia. Flange Outer Edge Center of Spindle Fig.4 Excessive Offset (For Smaller Hole Diameter) Center Height djustment 1 Center Height of the Inner Insert When installing inner insert as shown in Fig.1, it will be set around.5mm (.") below the Center of Spindle. (Fig.5) This is the normal position of the center height. However, in case that the turret of the lathe is out of alignment with the Center of Spindle, sometimes the inner insert may be above or below center. For stable machining, it is essential to check the Center Height of the inner insert carefully bout. below the Center Center of Spindle How to Check the Center Height For checking the center height of the inner insert, see the core which remains at the center of the bottom of the drilled hole. If the center height is in the normal position, a core of about.5mm (.") in diameter, will remain after machining. (Fig.6) djustment of center height is required if no core is present or a large core diameter of 1mm (") or more remains. * The drilled hole for verification purposes needs to be machined at approximately 1mm (.375") in depth and at a feed rate of.4 ipr or lower. Core (bout.5mm in Diameter) Fig.6 Center Core Fig.5 Front View of the Drill 17

18 Center Height djustment Continued... 3 Center Height djustment 1. When there is no remaining core and the inner insert is chipping This occurs when the inner insert is set above center. (Fig.7) How to djust.install the drill rotated by 18 Most problems will be solved by this method (Fig.8) B. If the core diameter becomes too large after the above adjustment, install the drill by rotating 9 counter-clockwise as shown in Fig.9 (outer edge is positioned lower) and adjust the center height by moving the tool in the X-axis direction. (However, this will make it impossible to adjust the cutting diameter) Caution: When installing the drill in the opposite direction (outer insert is positioned above), the cutting diameter will become smaller, which may cause the drill body to interfere with the drilled hole. The best solution is to readjust the center position of the turret itself. Fig.7 Insert breakage near the center of the drill 18 Rotation Initial Installation (Inner insert positioned higher than normal) Improved Position of Inner Insert (Inner Insert Positioned Lower than Normal) Center of Spindle Center of Spindle 9 Rotation Center Height djustment by Moving the Tool Higher Below the Center Center of Spindle 9 Center of Drill Center of Drill Outer Edge Center of Drill Close-up Near the Center Close-up Near the Center Close-up Near the Center Inner Insert Positioned too Far below Center Fig.8 Fig.9. Core with Excessively Large Diameter More than 1mm (") This occurs when the inner insert is below center This condition causes poor chip evacuation and an adjustment is required. Inner insert is positioned excessively below the center. 9 Rotation Center Height djustment by Moving the Tool Outer Edge How to djust Outer Edge Below the Center Higher 9 Install the drill rotated 9 as shown in Fig.1. (outer insert is positioned on the upper side) and adjust the center height by moving tool in the X-axis direction. (However, this will make it impossible to adjust the cutting diameter) Caution: When installing the drill in the opposite direction (outer insert is positioned lower), the cutting diameter will become smaller, which may cause the drill body to interfere with the drilled hole. The best solution is to readjust the center position of the turret itself. Fig.1 18

19 Insert Grade Selection Guide Select CVD for the outer edge when performing high speed and high efficiency drilling and for abrasion resistance and long tool life. Select PVD MEGCOT for the outer edge for stable machining and a better surface finish. PVD MEGCOT is recommended for the outer edge if chattering occurs, machining with lathe, or if cutting conditions cannot be increased to the recommended speed for CVD. 1st Recommendation (High Speed and High Efficiency Machining) Stable Machining Oriented (1st Recommendation for Lathe Machining) Outer Edge : CVD(C5D / C415D) : PVD (PR1535) Outer Edge : PVD (PR15) : PVD (PR1535) Shape of the Hole Bottom DRV Inch Diameters (in) Insert Size (SCMT..) Insert Size (SCMT..) DRV Metric Diameters (mm) Insert Size (SCMT..) Common for D, 3D, 4D, 5D, 6D Drills *bove is estimated values. (varies within ±.1mm (.4") depending on workpiece material and cutting conditions) Machining Caution In case of through-hole machining, a disc may be generated and ejected outward when exiting the hole. Be sure to install guards to protect against dangers if using a machine without the covers (including general-purpose lathes, etc.). Disc 19

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