CP157-E. Heavy Milling. MSR Type. BT50 Integral Arbor type. Heavy Milling Cutter. PR830(For Steel) PR905(For Cast Iron) New! Low resistance insert

Transcription

1 CP157-E Heavy Milling Type Heavy Milling Cutter BT50 Integral Arbor type PR830(For Steel) PR905(For Cast Iron) New! MonSteR M S R Mill Low resistance insert

2 Heavy Milling Cutter Advantages Nicked insert lowers and disperses resistance at milling, and enables high feed rate by restraining chattering. Improve chip evacuation and low resistance by special chipbreaker. Enables heavy milling and deep cutting, and also drastically improves machining efficiency. (Reduction of machining time) Nicked Insert Comparison of cutting resistance Kyocera Competitor A Competitor B Nick Nick 11 Type 17 Type APMT25 Type Size Comparison (Full Size) Cutting Resistance Combined Force Combined Force By Nicked and exclusive chipbreaker, low resistance and chip evacuation is improved. Internal evaluation Combined Force High Efficient Heavy Milling 1

3 Type Fig.1 Fig.2 Fig.3 Fig.4 Fig.5 Fig.6 Toolholder Dimension(Bore φd: inch ) Dimension (mm) Stock No. of Insert No. of Line No. of Stage Rake Angle φd φd φd1 φd2 H E a b S A.R. R.R. Shape Weight Spare Part Clamp Screw Wrench Shim Clamp Screw Wrench Anti-seize Compound 063R Fig R Fig R Fig R Fig R Fig R Fig R Fig R Fig R Fig R Fig R Fig R Fig R Fig R Fig R Fig R Fig R Fig R Fig SB- 120TR TT-25L MAP SB TR Shim is not available for 063R (Dia. D=63). :Standard Stock :Check Availability Arbor attachment bolt(hh12x40) is included for 063R/080R. It is not recommended using only top edge part (D.O.C 30mm) for 4 stages type.if D.O.C is small, use 1 stage or 2 stages type. Deep grooving is not recommended for this cutter. Toolholder Dimension(Bore φd: mm ) Dimension (mm) Stock No. of Insert No. of Line No. of Stage Rake Angle φd φd φd1 φd2 H E a b S A.R. R.R. 063R-1M Fig R-2M Fig R-1M Fig R-2M Fig R-4M Fig R-1M Fig R-2M Fig R-4M Fig R-1M Fig R-2M Fig R-4M Fig R-1M Fig R-2M Fig R-4M Fig R-1M Fig R-2M Fig R-1M Fig R-2M Fig Shape Weight Spare Part DT-15 Clamp Screw Wrench Shim Clamp Screw Wrench SB- 120TR TT-25L MAP SB TR Shim is not available for 063R (Dia. D=63). :Standard Stock :Check Availability Arbor attachment bolt(hh12x40) is included for 063R/080R. It is not recommended using only top edge part (D.O.C 30mm) for 4 stages type.if D.O.C is small, use 1 stage or 2 stages type. Deep grooving is not recommended for this cutter. Coat seizing inhibitor () thinly on clamp screw when insert is fixed. for Insert Clamp for Insert Clamp for Shim Clamp for Shim Clamp DT-15 Anti-seize Compound Cutting Conditions (Dia. 100mm) 100R-2 (6 edge lines 2 Stage) (ref.)d.o.c. and Chip Evacuation Work Material Cutting Conditions D.O.C. Evacuation D.O.C. Evacuation Carbon Steel S C Alloy Steel SCM Not recommended for Stainless Steel V=150m/min (N=478min -1 ) V=120m/min (N=382min -1 ) f=0.25mm/ 刃 tooth (F=718mm/min) dxw 40mm X 20mm f=0.2mm/ 刃 tooth (F=458mm/min) 574 cc/min 367 cc/min dxw 40mm X 40mm 1147 cc/min 733 cc/min 2

4 -BT50 Fig.1 Fig.2 Holder Dimension (BT50 Integral Arbor Type) Dimension (mm) Rake Angle Spare Part Stock No. of Insert No. of Line No. of Stage φd L S A.R. R.R. Shape Weight Clamp Screw Wrench Shim Clamp Screw Wrench Anti-seize Compound 063R-BT Fig R-BT50-5 受 Fig R-BT SB-120TR TT-25L Fig MAP-2506 SB-40140TR DT R-BT50-5 受 Fig for Insert Clamp 100R-BT Fig for Shim Clamp R-BT50-5 受 Fig Shim is not available for 063R (Dia. D=63). :Standard Stock 受 : 受注生産 It is not recommended using only top edge part (D.O.C 30mm) for 4 stages/5 stages type. If D.O.C is small, use previous page's 1 stage type or 2 stages type. Deep grooving is not recommended for this cutter. Coat seizing inhibitor () thinly on clamp screw when insert is fixed. Applicable Insert Shape 3-Nicked 4-Nicked APMT 2508ER-NB3 Dimension (mm) Angle PVD Coated Applicable Tool holder A T φd W R α β γ PR6 PR830 PR905 APMT ER-NB APMT ER-NB APMT 2508ER-NB APMT ER-NB APMT ER-NB M M APMT ER-NB3P M Low resistance 3 nicks APMT ER-NB4P M Low resistance 4 nicks Caution at installing Nicked Insert When installing Nicked Insert, it is important to install it in the correct position. When it is installed wrong, the Tool cannot machine the work and it may damage the tool holder body. For Type, Nicked Insert location indicator is marked at Insert attached area. Please be minded followings when you attach Inserts to tool holders. Indication is marked near the Insert pocket for type. 1)In case of Indicator 3, AP ER-NB3 2)In case of Indicator 4, AP ER-NB4 (Example of No Inserts) No. of Insert No. of Line :Standard Stock No. of Inserts Nicked NB3 NB R R R When attaching the insert with corner-radius 4.0mm, the additional processing to the body is needed. Apply additional processing to the body corner according to the chart hereunder. Insert Corner-R Additional Processing Dimension (mm) to Body Corner 4.0 R2.0 Round- shaped additional processing is recommended. When applying chamfer- shaped additional processing, Body Corner do not cut away too much. Pre-processing Additionally Processed Post-processing Insert with Large Corner-R

5 Case Studies S45C SS400 Plate V=140m/min (N=446min -1 ) dxw=43x15mm f=0.2mm/tooth (F=535mm/min) Base V=150m/min (N=478min -1 ) dxw=40x15mm f=0.15mm/tooth (F=430mm/min) 100R-2 100R-2 Chip evacuation=345cc/min Chip evacuation=258cc/min Competitor Cutter C Chip evacuation=33cc/min Competitor Cutter D Chip evacuation=43cc/min Since is able to evacuate chips more than 10 times comparing with competitor Cutter C [dia 125mm (6 Edges) V=120m/min f=0.1mm/tooth (F=184mm/ min) dxw=6x30mm] chip evacuation= 33cc/min, the cutting time is drastically improved. Since is able to deepen doc comparing with competitor Cutter D [dia 100mm (6 edges) V=150m/min f=0.12mm/tooth (F=344mm/min) dxw=5x25mm] chip evacuation=43cc/min, the cutting time is drastically improved. SS400 S35C Base Plate V=200m/min (N=640min -1 ) dxw=75x10mm f=0.1mm/tooth (F=385mm/min) Bracket V=150m/min (N=478min -1 ) dxw=20x70mm f=0.25mm/tooth (F=718mm/min) 100R-4 100R-2 Chip evacuation=289cc/min Chip evacuation=1005cc/min Competitor Cutter E Chip evacuatione=114cc/min Competitor Cutter F Chip evacuation=417cc/min Since is able to cut by doc d=75mm comparing with competitor Cutter E [dia 100mm (4 edges) V=250m/min f=0.1mm/tooth (F=320mm/min) dxw=36x10mm] chip evacuation= 114cc/min, the cutting efficiency is improved 2.5 times. Since is able to cut stably even by increasing feed rate 2.4 times comparing with competitor Cutter F [dia 100mm (6 edge lines) V=130m/min f=0.12mm/tooth (F=298mm/min) dxw=20x70mm], cutting efficiency is drastically improved.

6 Case Studies Special Steel Electric generator part V=200m/min N=637min -1 dxw=40 x 25mm f=0.11mm/tooth F=420mm/min 100R-2 850mmOver hang 2 pc/1hr (Efficiency 4 times) Competitor Cutter G 0.5 pc/1hr Competitor Cutter G took 2 hours to machine 1 workpiece, but can machine 1 workpiece by 30 min and machining efficiency is improved 4 times. SS400 FCD450 Plate V=200m/min (N=640min -1 ) Construction machine part V=173m/min (N=550min -1 ) dxw=80x10mm f=0.06mm/tooth (F=230mm/min) Weak workpiece clamp and easy cause of chattering 350mmOver hang dxw=5x50mm f=0.2mm/tooth (F=6mm/min) 230mm (Over hang) 100R-4 (4 stage type) 100R-2 (PR905) Chip evacuation = 184cc/min Chip evacuation=165cc/min Competitor Cutter H Chip evacuation = 78cc/min Competitor Cutter I Chip evacuation=51cc/min Against chip evacuation = 78cc/min of Competitor Cutter H [Dia. 100mm(4 edges) V=250m/min f=0.06mm/tooth (F=200mm/min) dxw=39x10mm], since cutting depth (d) is larger for, chip evacuation is 184cc/min, then machining efficiency is improved 2.3 times and realized quiet machining noise. Against chip evacuation = 51cc/min of Competitor Cutter I[Dia. 100(6 edges) V=90m/min f=0.2mm/tooth(f=343mm/min) dxw=3x50mm], since cutting depth (d) is larger for, chip evacuation is 165cc/min, then machining efficiency is improved 3.2 times. 5

7 Case Studies SC450 Construction machine part V=125m/min (N=400min -1 ) dxw=15x45mm f=0.15mm/tooth (F=3mm/min) 100R-2 Chip evacuation = 244cc/min Competitor Cutter J Chip evacuation = 122cc/min Since even increasing feed ratio as 2 times, stable machining was possible and machining efficiency was improved compared with Competitor Cutter J[Dia. 100(4 edges) V=125m/min f=0.08mm/tooth (F=180mm/min) dxw=15x45mm] SC450 (Cast Steel) SS400 Construction machine part V=150m/min (N=750min -1 ) dxw=20 x 8mm(Max) f=0.25mm/tooth (F=750mm/min) Plate V=125m/min (N=400min -1 ) dxw=25 x 5mm f=0.15mm/tooth (F=400mm/min) 63R-4 4 edge lines (PR905) 100R-2 Chip evacuation = 120cc/min Chip evacuation = 50cc/min Competitor Cutter K Chip evacuation = 29cc/min Competitor Cutter L Chip evacuation = 7.4cc/min Compared with Competitor Cutter K chip evacuation = 29cc/min, shows chip evacuation = 120cc/min and machining efficiency is improved 4.1 times with less vibration and quiet machining noise. Compared with Competitor Cutter L chip evacuation = 7.4cc/min, shows chip evacuation = 50cc/min and machining efficiency is improved 6.7 times with less vibration and quiet machining noise.

8 Cutter Q & A Q.1 A.1 What is the most recommended cutting condition for? 1V=150m/min, f=0.2mm/tooth, Large longwise D.O.C and less transversal In case of 100R-2 e.g)loadmeter 120% e.g)loadmeter 90% Q.5 A.5 Is FC/FCD machining possible? Able to cutt FC/FCD There is a record of FC as 1800cc/min. Basically machinability is better than steel and there is no problem. Q.2 A.2 1 pass 2 pass 3 pass L o n g w i s e X Transversal: 15X75mm 3 pass Longwise X Transversal: 45X25mm 2 pass Judgment standard of usability 1 pass Maximum revolution has to be less than 4000 min-1. Being over BT50 Q.6 A.6 Recommended cutting condition V=150m/min f=0.3mm/tooth * In case of causing wear, PR905(PR830) is recommended. How is the insert life (Time.Distance)? Chip weight: 700kg/Corner (Result by PR6) Machining time: 90min (calculated value) Machining distance: 65m (calculated value) * This tool is available for gantry machines. The reason why this is not usable under high revolution machine is because enough torque cannot be gained. What is efficiency 1000cc/min? About 7.8kg chip evacuation per 1min Tool life time = 700kg (Chip weight) 7.8kg (Chip evacuation amount per 1min) = 90min * There are positive results for BT40, feed ratio will be about f=0.1mm/tooth. Machining distance= 90min (Time by the end of tool life) x 717mm/min (Table feed ratio per 1min)=65m * In case of V=150m/min, longwise x transversal: 20 x70mm, F=717mm/min Q.3 Caution points in case of less power machine * Tool: 100R-2 (6 edges) A.3 Please do not use large machining dia. Q.7 How to resolve chattering. Dia.63 or Dia.80mm is recommended. Please set up conditions checking which part is most powerful confirming machine torque curve. Tried under condition of V=150m/min, enough torque was not gained because of high gear. In this case, it has to be prioritized using V which can exert enough torque as V=120m/min. A.7 It is recommended using V=150m/min for, if chattering is caused under machining environment, following condition is recommended. In case of chattering Basically decrease cutting speed (V), increase feed ratio(f) Please increase cutting speed and decrease feed ratio. * Machine torque curve will be prioritized. In case of general steel V=80m/min f=0.25mm/tooth In case of FC/FCD V=80m/min f=0.35mm/tooth Q.4 Caution point of Weak clamp A.4 Decrease feed ratio at start cutting workpiece * Almost all case of moving workpiece is identified at start cutting workpiece. Effective for increasing cutting speed and decrease feed ratio V=150m/min, f=0.2mm/tooth V=200m/min, f=0.15mm/tooth