Hochleistungsplanfräser Fraise à haut rendement Fresa frontale ad alta prestazione

Size: px

Start display at page:

Download "Hochleistungsplanfräser Fraise à haut rendement Fresa frontale ad alta prestazione"

Alban Gilmore
5 years ago
Views:

MFPN FACE MILL High efficient Face Mill Double Sided

Tough by Large Dual Cutting Edge Insert.

Hochleistungsplanfräser Fraise à haut rendement

Schneidwinkeln. Hervorragende Spanabfuhr.

à 2 arêtes. Excellente évacuation des copeaux.

1 MFPN FACE MILL High efficient Face Mill Double Sided Pentagonal Insert. Tough by Large Dual Cutting Edge Insert. Excellent Chip Evacuation. Low Cutting Force. Hochleistungsplanfräser Fraise à haut rendement Fresa frontale ad alta prestazione Doppelseitige pentagonale Wendeschneidplatte. Sehr große und zähe WSP mit unterschiedlichen Schneidwinkeln. Hervorragende Spanabfuhr. Geringe Schnittkräfte. Plaquette pentagonale réversible. Bien résistante grâce à la large plaquette de coupe à 2 arêtes. Excellente évacuation des copeaux. Faible force de coupe. Inserto pentagonale a doppio lato. Tenacità grazie all inserto di grandi dimensioni con doppio tagliente. Evacuazione del truciolo eccellente. Bassi sforzi di taglio. TZZ

Double Sided Pentagonal Insert Doppelseitige pentagonale Wendeschneidplatte Plaquette

and optimized insert holding system by 2 faces.

10 arêtes de coupe par plaquette et optimisation du serrage par 2 points d appui.

inserto. 12 10 8 MSRS 5 4 3 2 Conventional MFPN 0.5 0.

7 Twoface holding Zwei Anlagefl ächen Tenue deux faces Supporto bifacciale Primary

stabilized accuracy due to optimized holding angle of insert against the cutting

Stabilité accrue grâce à l optimisation du systeme de serrage de la plaquette.

Cutting Force Geringe Schnittkraft Faible force de coupe Bassi sforzi di taglio Good

Gute Schnittigkeit für besseren Eingriff ins Werkstück.

Buon effetto di troncatura permette una migliore presa del pezzo.

2000 100 1200 800 400 0 Comparison of cutting force Vergleich Schnittkraft

comparison with competitor A 14% reduction in comparison with GM GM SM Competitor A

Toughness) Schneide mit unterschiedlichen Schneidwinkeln (Hohe Zähigkeit) Double

$Comparison of fracture resistance Vergleich Bruchfestigkeit Comparaison de résistance$ edge Primary cutting edge PNMU1205ANERGM (PR1225) Competitor C (PVD negative insert)

edge Primary cutting edge PNMU1205ANERGM (PR1225) Competitor C (PVD negative insert)

2 Double Sided Pentagonal Insert Doppelseitige pentagonale Wendeschneidplatte Plaquette pentagonale réversible Inserto pentagonale a doppio lato 10 cutting edges per insert and optimized insert holding system by 2 faces. 10 Schneiden pro Wendeschneidplatte und optimaler Plattensitz mit zwei Anlagefl ächen. 10 arêtes de coupe par plaquette et optimisation du serrage par 2 points d appui. 10 taglienti per inserto e sistema ottimizzato per il supporto bifacciale dell inserto MSRS Conventional MFPN ap (mm) Depth of cut fz (mm/t) Feed per tooth 0.7 Twoface holding Zwei Anlagefl ächen Tenue deux faces Supporto bifacciale Primary cutting edge Hauptschneide Principale aretes de coupe Primo tagliente Highly stabilized accuracy due to optimized holding angle of insert against the cutting force. Höhere Genauigkeit durch verbesserten Anstellwinkel gegen die Schnittkraft. Stabilité accrue grâce à l optimisation du systeme de serrage de la plaquette. Precisione altamente stabile grazie all ottimizzazione dell angolo di supporto dell inserto contro la forza di taglio. Cutting edge angle Schnittwinkel Angle d arête de coupe Angolo del tagliente Low Cutting Force Geringe Schnittkraft Faible force de coupe Bassi sforzi di taglio Good shearing effect provides better bite into workpiece. Gute Schnittigkeit für besseren Eingriff ins Werkstück. Très bonne formation de copeaux dès le début de l attaque de la pièce. Buon effetto di troncatura permette una migliore presa del pezzo. +10 High Axial Rake Angle (Max.+10 ). Großer axialer Spanwinkel (Max. +10 ). Angle axial très positif (Max. +10 ) Alto angolo assiale di inclinazione (massimo +10 ) Cutting force comparison Comparison of cutting force Vergleich Schnittkraft Comparaison des force de coupe Comparazione degli sforzi di taglio 1% reduction in comparison with competitor A 14% reduction in comparison with GM GM SM Competitor A Competitor B Principal force Feed force Back force Dual Cutting Edge Design (High Toughness) Schneide mit unterschiedlichen Schneidwinkeln (Hohe Zähigkeit) Double arête de coupe réversible (grande ténacité) Design a doppio tagliente (alta tenacità) Comparison of fracture resistance Vergleich Bruchfestigkeit Comparaison de résistance à la rupture Confronto della resistenza alla frattura Wiper edge Secondary cutting edge Primary cutting edge PNMU1205ANERGM (PR1225) Competitor C (PVD negative insert) Competitor D (PVD negative insert) No. of impacts fz=0.5mm/t fz=0.mm/t fz=0.7mm/t No cracks Insert cracks 0.5mm/t 0.mm/t 0.7mm/t Primary Edge makes chips thinner and reduces impact force. Die Hauptschneide produziert dünnere Späne und reduziert Schnittkräfte. Grâce à l arête de coupe primaire reduction des efforts d attaque et naissance de copeaux fi ns. Il primo tagliente produce un truciolo fi ne riducendo le forze di impatto. ~ 1

Long tool life with Lange Werkzeugstandzeit mit Longue durée de vie d outil grâce au revêtment Lunga vita utensile grazie al rivestimento Wear

10 Competitor E Competitor F Hardness(GPa) 20 10 TiCN TiN TiAlN 0.05 0.00 0 20 40 0 80 Cutting time [min].

Steel/Stainless steel Cast iron/titanium alloy Long tool life and highspeed milling due to high hardness and high oxidation resistance.

Longue durée de vie et haute vitesse de coupe augmentée grâce à une plus grande duretée et résistance à l oxydation.

Excellent Chip Evacuation Hervorragende Spanabfuhr Excellente evacuation de copeaux Evacuazione del truciolo eccellente Smooth chip evacuation reduces

3 Long tool life with Lange Werkzeugstandzeit mit Longue durée de vie d outil grâce au revêtment Lunga vita utensile grazie al rivestimento Wear comparison Vergleich des Verschleißverhaltens Comparaison des usures Confronto usura TiC Flank wear [mm] Competitor E Competitor F Hardness(GPa) TiCN TiN TiAlN Cutting time [min]. Competitor G PR Insert Grades (PVD coated carbide) PR1225 PR1210 Oxidation temperature Workpiece Material Steel/Stainless steel Cast iron/titanium alloy Long tool life and highspeed milling due to high hardness and high oxidation resistance. Lange Standzeit und hohe Geschwindigkeiten durch hohen Härtegrad und Oxidationsbeständigkeit. Longue durée de vie et haute vitesse de coupe augmentée grâce à une plus grande duretée et résistance à l oxydation. Lunga vita utensile e fresatura ad alta velocità per merito della durezza e dell alta resistenza all ossidazione. Excellent Chip Evacuation Hervorragende Spanabfuhr Excellente evacuation de copeaux Evacuazione del truciolo eccellente Smooth chip evacuation reduces chipbiting. Reduzierterter Spanschlag durch leichte Spanabfuhr. Design de la plaquette réduit les copeaux sur l arête de coupe. L evacuazione dei trucioli senza attrito, riduce l impatto dei trucioli. Chipbreaker Applications Shape SM GM General SM Low cutting force ap (mm) Depth of cut 3 GM GH 1 GH Heavy milling fz (mm/t) Feed per tooth 2

4 E A.R. R.R. Rake Angle( ) max +10 ød= 10 ød=80 8 ød=1002 ød b H E a a ød b ød b ø18 H H E ød2 ød1 ød ød1 45 ød1 ød ød1 45 ød2 ød1 ød ød1 ø2 45 Fig.1 Fig.2 Fig.3 Holder Dimension Description Standard No. of Insert Dimension (mm) ød ød1 ød ød1 ød2 H E a b Shape Weight (kg) Shim Bore Dia. mm spec Bore Dia. Inch spec Extra fi ne pitch Fine pitch Coarse pitch Extra fi ne pitch Fine pitch Coarse pitch MFPN 4R4TM Fig.1 480R5TM RTM Fig R7TM R8TM R10TM Fig R12TM MFPN 4R5TM Fig.1 480RTM R8TM Fig R10TM R12TM R14TM Fig R1TM MFPN 4RTM Fig.1 480R8TM R10TM Fig R13TM R1TM R18TM Fig R20TM MFPN 480R5T Fig RT R7T Fig R8T R10T Fig.3 452R12T MFPN 480RT Fig R8T R10T Fig R12T R14T Fig.3 452R1T MFPN 480R8T Fig R10T R13T Fig R1T R18T Fig.3 452R20T Yes Yes Standard Item Check Availability 3

5 Spare parts from (mm/inch common spec) Spare Parts Description Clamp Screw TT Wrench DTM Shim Shim Screw Wrench Arbar Clamp Screw Coarse pitch Fine pitch Extra fi ne pitch MFPN 4R4TM HH10x30 MFPN 480R5TM SB140TR TT15 MFPN45 SPW70 LW5 HH12x40 MFPN 45100RTM for Insert Clamp Recommended torque is 4.2 Nm. for Insert Clamp Recommended torque is.0 Nm. 452R12TM MFPN 4R5TM HH10x30 MFPN 480RTM SB140TR TT15 HH12x40 MFPN 45100R8TM for Insert Clamp Recommended torque is 4.2 Nm. 452R1TM MFPN 4RTM HH10x30 MFPN 480R8TM SB40140TRN DTM15 HH12x40 MFPN 45100R10TM for Insert Clamp Recommended torque is 3.5 Nm. 452R20TM ~ ~ ~ Classifi cation of usage P Steel Die Steel Milling Inserts (with hole) Shape Handled insert indicates RightHand Roughing / 1st Choice Roughing / 2nd Choice Finishing / 1st Choice Finishing / 2nd Choice (Hardened material is applicable only under 45HRC) Description M Stainless Steel K Gray Cast Iron Nodular Cast Iron N Nonferrous Material S Heatresistant Alloy Titanium alloy H Hardened material Dimension (mm) carbide A T ød X Z PR1225 PR1210 Z A Ød PNMU 1205ANERGM General X T Z A Ød PNMU 1205ANERSM Low cutting force X T Z A Ød PNMU 1205ANERGH Tough Edge (for heavy milling) X T Standard Item Check Availability Reference for selecting a facemill and insert suitable for each milling purpose Milling Purpose Coarse pitch Facemilltype Fine pitch Extra fi ne pitch Chipbreaker General milling of steel and alloy steel Steel and alloy steel (at chattering due to low rigidity machine or poor clamping power) Productivity oriented (Running cost decrease) General milling of stainless steel Stainless steel (at chattering due to low rigidity machine or poor clamping power) Cast iron (for processing effi ciency improvement) Cast iron (Over ap=4 mm, over fz=0.35 mm/t) 4

6 Face milling (with meltdown surface) ø MFPN facemill enables stable milling due to reduced chipbiting and edge cracks. MFPN facemill, no chattering, showed 3 times longer tool life than competitor. MFPN facemill showed 1.5 times longer tool life than the competitor. High feed rate of MFPN allowed 1.3 times higher milling efficiency compared to the competitor. Total D.O.C. 100 ø400 Face milling MFPN facemill showed 2 times longer tool life than competitor. Competitor caused cracks by chipbiting. MFPN facemill had no cracks and allowed stable milling. MFPN facemill enabled twice the table feed rate compared with the competitor. Milling efficiency improved twofold. Highly stable milling into the entrance of workpiece and less vibration than the competitor. Cleanly curled chips which barely cause chipbiting. Cutting speed has been changed Vc=110 m/min of conventional competitor's to Vc=130 m/min, thereby the milling efficiency of MFPN increased 1.2 times. 5

7 End face milling ø90 Although the conventional tool causes chattering, MFPN facemill suppresses chattering, enabling stable milling. Even if the feed rate is raised to 1.9 times, the insert wears less and there is no cracks on the insert. Both the milling efficiency and the tool life have been improved. MFPN facemill causes no vibration, enabling stable milling, even though the number of cutting edges of facemill has been increased by 4 and the feed per tooth has been increased by 1.3 times. Does not generate much heat after milling and obtains the lustrous surface finish without burrs. Milling efficiency increased 2. times with the high cutting conditions (Conventional) Vc=140m/min apxae=3x80mm fz=0.11mm/t (Vf=230mm/min) Even if the cutting speed and feed rate are raised up to the level of the conventional tool, the tool life of MFPN remains unchanged and milling efficiency increases by 2. times. MFPN vibrates less right at entrance and exit on workpiece with reduced cutting sound. Even when the cutting depth, cutting speed and feed rate cannot be raised due to the low rigidity of a workpiece, MFPN facemill enables stable milling without chattering and also has an improved tool life of 1.5 times.

1. Be sure to remove dust and chips from the insert mounting pocket. 2.

1 and Fig. 2. Recommended tightening torque The torque for coarse pitch and cross pitch (using M5 screw) is 4.2 Nm. The torque for extra cross pitch (using M4 screw) is 3.

After tightening the screw, make sure that there is no clearance between the insert seat surface and the bearing surface of the holder and between the insert side surfaces and the constraint surface

To protect the wiper edge, use the corners of insert in the sequence of corner numbers.

8 1. Be sure to remove dust and chips from the insert mounting pocket. 2. After applying antiseize compound, while pressing the insert against the constraint surfaces, put the screw into the hole of the insert and tighten the screw with appropriate torque. See Fig. 1 and Fig. 2. Recommended tightening torque The torque for coarse pitch and cross pitch (using M5 screw) is 4.2 Nm. The torque for extra cross pitch (using M4 screw) is 3.5 Nm. 3. After tightening the screw, make sure that there is no clearance between the insert seat surface and the bearing surface of the holder and between the insert side surfaces and the constraint surface of the holder. 4. To change the cutting edge of the insert, turn the insert counterclockwise (see Fig. 3). Insert corner identifi cation number is stamped on the top surface of insert (Fig. 4). To protect the wiper edge, use the corners of insert in the sequence of corner numbers. Side surface of insert Top surface of insert Constraint surface Insert corner identification number (mm/t) Workpiece Material Insert Grade Cutting Speed (m/min) Chipbreaker GM Carbon Steel PR ~180~2 SM GH GM Alloy Steel PR ~10~220 SM GH GM Die Steel PR ~140~180 SM GH Stainless Steel PR ~1~200 GM SM GM Gray Cast Iron PR ~180~2 SM GH GM Nodular Cast Iron PR ~1~200 SM GH Titanium Alloy PR ~~70 SM Coarse pitch (with shim) Type Fine pitch (without shim) (For GH chipbreaker, recommend under fz=0.4 mm/t.) Extra fi ne pitch (without shim) The use of the GH breaker is not recommended. The boldfaced number indicates a center value of recommended condition. : 1st Recommendation : 2nd Recommendation KYOCERA Fineceramics GmbH Hammfelddamm, 4140 Neuss, Germany Phone: +49 (0) Fax: +49 (0) / ceratip@kyocera.de KYOCERA Fineceramics SAS. 4, allee du Commandant Mouchotte Parayvieilleposte 91781,Wissous Cedex, France Phone: +33 (0) Fax: +33 (0) KYOCERA Fineceramics GmbH sp. z o.o. Poland Branch Office Leg. ul.europejska 4, 55220, JelczLaskowice, Poland Phone: +48(0) Fax: +48(0) KYOCERA Fineceramics GmbH Italy Branch Office Via Torino 51, Milan, Italy Phone: Fax: KYOCERA Fineceramics GmbH Spain Branch Office Avenida Manacor 4, Las Matas, Madrid, Spain Phone: Fax:

Milling Cutter for Heavy Roughing

15 15 Milling Cutter for Heavy Roughing Notched insert reduces cutting force, chattering and enables efficient cutting. Large depth of cut and high feed rate enable high effi ciency cutting. TZE00047 changes