Cost-eff ective shoulder milling cutter for high productivity

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Melina Cobb
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1 MillLine Tungaloy Report No. 51-G DOFORCE-TRI Cost-eff ective shoulder milling cutter for high productivity

2 ACCELERATED MACHINING

3 MillLine DoForce-Tri is a new series of tools with double-sided triangular insert performing general milling applications with superior advantages.

High-precision shoulder milling cutter with economical double-sided

advantage - Fully effective cutting edge length in square shoulder milling -

optimized rake angle form barrel-shaped chips, delivering smooth chip

4 High-precision shoulder milling cutter with economical double-sided triangular inserts Insert features: - 6-cornered design for economic advantage - Fully effective cutting edge length in square shoulder milling - Low cutting force even in large depth of cut - Concave cutting edge & optimized rake angle form barrel-shaped chips, delivering smooth chip evacuation 11 mm Depth of cut: ap (mm) ap = 11 mm ap = 6 mm Workpiece material: carbon steel 4 DOFORCE-TRI

ACCELERATED MACHINING INSERT TYPES TNMU-MJ with built-in wipers TNGU-MJ with built-in wipers - Available in M-class tolerance - Wiper edge for high-quality surface finish - Ground insert for high

TNMU-MJ Radius insert TNMU-NMJ Serrated insert - Insert with round corner for high toughness - Large rake angle reduces cutting force.

5 ACCELERATED MACHINING INSERT TYPES TNMU-MJ with built-in wipers TNGU-MJ with built-in wipers - Available in M-class tolerance - Wiper edge for high-quality surface finish - Ground insert for high wall accuracy - Unique flank design on the corner allows wiper to be effective all 6 edges. TNMU-MJ Radius insert TNMU-NMJ Serrated insert - Insert with round corner for high toughness - Large rake angle reduces cutting force. - Insert shape suitable for both R- & L-hand* cutter bodies (*: Left-hand body will be available upon reguest.) TNGU-NMJ Serrated insert - Available in M-class tolerance - Serrated cutting edges create small chips, reducing cutting force and chip volume. - Eliminates vibration on long-overhang tool - Suitable for large depth of cut in face milling - Each insert has asymmetrical serrations on the cutting edge of Side-A and Side-B to achieve good wall surface quality*. * Side A and Side B must be placed alternately in adjacent pockets. Note: Side A ad Side B can be identified by locating the tapered serration on the insert flank as high-lighted below in red. B A A A or B In case step marks appear on the surface as shown above, re-arrange the inserts in order. A B Asymmetrical groove on sides A and B Either side B A Insert positioning for the cutter with pockets in odd number 5

$Rich grade lineup for every kind of material - A total of four grades, including two new CVD grades TUNGALOY AH3135 Steel Stainless - PVD grade for high fracture resistance - Most suitable for steel$

6 Rich grade lineup for every kind of material - A total of four grades, including two new CVD grades TUNGALOY AH3135 Steel Stainless - PVD grade for high fracture resistance - Most suitable for steel and stainless steel in general cutting parameters AH12 - PVD grade with a well-balanced wear and fracture resistance - Ideal for general machining of steel and stainless steel T1215 Steel Cast iron Cast iron - CVD grade with outstanding wear and chipping resistance - Best for cast iron at high-speed machining T3225 Steel Stainless - CVD grade with excellent chipping and fracture resistance - Most suited for steel and stainless steel at high-speed machining TUNGALOY Special Surface Technology Enhanced coating resistance to chipping and peeling - Special surface post-treatment technology improves surface smoothness Superior wear resistance in high speed cutting - A thick alumina (Al2O3) layer improves insert life in a high cutting temperature generated during high speed machining Enhanced coating resistance to peeling - Strong adhesion between the carbide substrate and the coating layer improves coating resistance to peeling High High Cutting speed Vc (m / min ) Low T3225 AH3135 Steel Stainless Cast iron Cutting speed Vc (m / min ) Low T1215 AH12 Face milling Shoulder milling Face milling Shoulder milling 6 DOFORCE-TRI

7 ACCELERATED MACHINING CUTTING PERFORMANCE Cutting force Cutting force: F (N) Cutter Insert : TPTN12M5B22.R5 (ødc = 5 mm, z = 1) : TNGU1278PER-MJ / AH3135 (Wiper) TNMU127R16PER-MJ / AH3135 (Radius) TNGU1278PER-NMJ / AH3135 (Serrated) Workpiece material: S55C / C55 (2HB) Cutting speed : Vc = 15 m/min Feed per tooth : fz =.15 mm/t Depth of cut : ap = 5 mm Width of cut : ae = 3 mm Coolant : Dry Machine : Vertical M/C, BT5, 3kW Wiper Radius Serrated Concave cutting edge and optimized rake angle reduce cutting force. Surface roughness Surface roughness: Ra (µm) Wiper Cutter : TPTN12M5B22.R5 (ødc = 5 mm, z = 5) Insert : TNGU1278PER-MJ / AH3135 Workpiece material: S55C / C55 (2HB) Cutting speed : Vc = 15 m/min Feed per tooth : fz =.2mm/t Depth of cut : ap = 5 mm Width of cut : ae = 3 mm Coolant : Dry Machine : Vertical M/C, BT5, 3kW Wiper edge achieves better surface finish. Wall accuracy H Gap H (µm) Cutter : TPTN12M5B22.R5 (ødc = 5 mm, z = 5) Insert : TNGU1278PER-MJ / AH3135 Workpiece material: S55C / C55 (2HB) Cutting speed : Vc = 15 m/min Feed per tooth : fz =.15 mm/t Depth of cut : ap = 5 mm x 4 passes Width of cut : ae = 15 mm Coolant : Dry Machine : Vertical M/C, BT5, 3kW Wiper Optimized cutting edge geometry provides high wall accuracy. 7

8 CUTTING PERFORMANCE Tool life in machining steel Max. flank wear : VBmax (mm) Cutter Insert Workpiece material Cutting speed Feed per tooth Depth of cut Width of cut Coolant Machine : TPTN12M5B22.R5 (ødc = 5 mm, z = 1) : TNMU1278PER-MJ / AH3135 : S55C / C55 (18HB) : Vc = 15 m/min : fz =.15 mm/t : ap = 5 mm : ae = 3 mm : Dry : Vertical M/C, BT Cutting length (m) Tool life in machining cast iron Max. flank wear : VBmax (mm) Cutter Insert Workpiece material Cutting speed Feed per tooth Depth of cut Width of cut Coolant Machine : TPTN12M5B22.R5 (ødc = 5 mm, z = 1) : TNMU1278PER-MJ / AH12 : FC25 / 25 / GG25 : Vc = 2 m/min : fz =.2 mm/t : ap = 5 mm : ae = 34 mm : Dry : Vertical M/C, BT Cutting length (m) Tool life in machining stainless steel Max. flank wear : VBmax (mm) Cutting length (m) Cutter Insert Workpiece material Cutting speed Feed per tooth Depth of cut Width of cut Coolant Machine : TPTN12M5B22.R5 (ødc = 5 mm, z = 1) : TNMU1278PER-MJ / AH3135 : SUS34 / X5CrNi18-9 : Vc = 15 m/min : fz =.15 mm/t : ap = 5 mm : ae = 3 mm : Dry : Vertical M/C, BT5 8 DOFORCE-TRI

ACCELERATED MACHINING Square shoulder milling cutters with double-sided triangular insert CUTTER - BORE TYPE DoForce-Tri TPTN12 A.R. = +4.2 ~ +4.7, R.R. = -15.4 ~ -11.

9 ACCELERATED MACHINING Square shoulder milling cutters with double-sided triangular insert CUTTER - BORE TYPE DoForce-Tri TPTN12 A.R. = +4.2 ~ +4.7, R.R. = ~ ødb ød a b R l R Lf R ap ødc 9 Designation Max. ap ødc z ødb Lf ød l a b Kg C.bolt Insert Torque* TPTN12M5B22.R CM1X3H TN*U TPTN12M5B22.R CM1X3H TN*U TPTN12M63B22.R CM1X3H TN*U TPTN12M63B22.R CM1X3H TN*U TPTN12J8B25.4R CM12X3H TN*U TPTN12J8B25.4R CM12X3H TN*U TPTN12M8B27.R CM12X3H TN*U TPTN12M8B27.R CM12X3H TN*U TPTN12J1B31.7R TMBA-M16H TN*U TPTN12J1B31.7R TMBA-M16H TN*U TPTN12M1B32.R TMBA-M16H TN*U TPTN12M1B32.R TMBA-M16H TN*U TPTN12J125B38.1R TMBA-M2H TN*U TPTN12J125B38.1R TMBA-M2H TN*U TPTN12M125B4.R TMBA-M2H TN*U TPTN12M125B4.R TMBA-M2H TN*U *Torque: Recommended torque (N m) for clamping SPARE PARTS Left-hand body will be available upon request - can be used only with TNMU-MJ insert Wrench Clamping screw Torx Bit Grip CSPB-3.5 BLDIP15/S7 H-TB2W L-hand cutter R-hand cutter TNMU-MJ radius type 9

Square shoulder milling cutters with double-sided triangular insert CUTTER - SHANK TYPE DoForce-Tri EPTN12 R ødc øds R R 9 ap Lf L ls Designation Max.

10 Square shoulder milling cutters with double-sided triangular insert CUTTER - SHANK TYPE DoForce-Tri EPTN12 R ødc øds R R 9 ap Lf L ls Designation Max. ap ødc z øds ls Lf L Kg Insert Torque* EPTN12M32C32.R2N TN*U EPTN12M32C32.R3N TN*U EPTN12M4C32.R3N TN*U EPTN12M4C32.R4N TN*U *Torque: Recommended torque (N m) for clamping SPARE PARTS Wrench Clamping screw Torx Bit Grip CSPB-3.5 BLDIP15/S7 H-TB2W On a cutter, the screw hole of an insert pocket is placed at an angle. Leave a gap between the insert and pocket when starting to fasten the screw on the cutter body as shown in Fig. A. After fastening the screw, please ensure that there is no gap between the cutter body and insert. (Fig. B) Leave a gap when starting to fasten the screw. Fig. A Fig. B 1 DOFORCE-TRI

11 ACCELERATED MACHINING INSERT TNMU-MJ TNGU-MJ ap T A TNMU-NMJ TNGU-NMJ TNMU-R-MJ ød bs rε Designation P Steel M Stainless K Cast iron N Non-ferrous S Superalloys H Hard materials rε Max. ap Coated AH12 AH3135 T1215 T3225 : First choice : Second choice A ød T bs TNMU1278PER-MJ TNGU1278PER-MJ TNMU1278PER-NMJ TNGU1278PER-NMJ TNMU127R16PER-MJ : product : Line up 11

12 STANDARD CUTTING CONDITIONS ISO Workpiece materials Hardness Priority Grades Chipbreaker Cutting speed Vc (m/min) Feed per tooth fz (mm/t) Low carbon steel (S15C / C15E4, SS4 / E275A, etc.) - 3 HB First choice AH3135 MJ HB Priority on wear resistance T3225 MJ HB For low cutting force AH3135 NMJ Carbon steel and alloy steel (S55C / C55, SCM44 / 42CrMo4, etc.) - 3 HB First choice AH3135 MJ HB Priority on wear resistance T3225 MJ HB For low cutting force AH3135 NMJ Prehardened steel (NAK8, PX5, etc.) 3-4 HRC First choice AH3135 MJ HRC Priority on wear resistance T3225 MJ HRC For low cutting force AH3135 NMJ Stainless steel (SUS34 / X5CrNi18-9, SUS316 / X5CrNiMo , etc.) - First choice AH3135 MJ Priority on wear resistance T3225 MJ For low cutting force AH3135 NMJ Grey cast iron (FC25 / 25, FC3 / 3, etc.) HB First choice AH12 MJ HB Priority on wear resistance T1215 MJ HB For low cutting force AH12 NMJ Ductile cast iron (FCD4, FCD6 / 6-3, etc.) HB First choice AH12 MJ HB Priority on wear resistance T1215 MJ HB For low cutting force AH12 NMJ Titanium alloys (Ti-6AI-4V, etc.) - First choice AH12 MJ For low cutting force AH12 NMJ Heat-resistant alloys (Inconel718, etc.) - First choice AH12 MJ For low cutting force AH12 NMJ Note: For NMJ chipbreaker, use the feed rate less than.15 mm/z. Designation Chip thickness (mm) TNMU1278PER-NMJ.2 TNGU1278PER-NMJ DOFORCE-TRI

13 ACCELERATED MACHINING PRACTICAL EXAMPLES Workpiece type Cutter Insert Grade Carrier Cylinder TPN12R63M22.E6 (ø63, z = 6) TPTN12J1B31.7R1 (ø5, z = 5) TNGU1278PER-MJ TNGU1278PER-MJ AH12 AH3135 Pearlitic cast iron (25 HB) S45C / C45 8 mm Workpiece material 25 mm ø3 5 mm Cutting conditions Cutting conditions Cutting speed: Vc (m/min) Feed per tooth: fz (mm/t) Feed speed: Vf (m/min) Depth of cut: ap (mm) Width of cut: ae (mm) Method of machining Coolant Machine Results Workpiece type Cutter Insert Grade Workpiece material Cutting speed: Vc (m/min) Feed per tooth: fz (mm/t) Feed speed: Vf (m/min) Depth of cut: ap (mm) Width of cut: ae (mm) Method of machining Coolant Machine Tool Life (pcs/corner) Machine base Plate TPTN12J1B31.7R1 (ø1, z = 1) TPTN12J1B31.7R7 (ø1, z = 7) TNMU1278PER-MJ TNGU1278PER-NMJ AH12 AH3135 FCD45 / 45-1S / GGG45 SM4A 2 mm Face milling Wet Horizontal M/C, BT5 The combination of special geometing and grade for inserts in DoForce-Tri series helps extend tool life compared to the competitor. 18 mm 1 mm Face milling Wet Horizontal M/C, BT5 Tool life 2.4 times! MRR (cm3/min) (z = 3) (z = 5) Optimized geometng of the DoForce-Tri insert reduces cutting force and allows more inserts to be used on a single cutter body, which improves productivity. 8 mm Face milling, Shoulder milling Air Vertical M/C, BT4 12 mm Productivity 1.8 times! 15 mm Face milling Dry Vertical M/C, BT5 Results MRR (cm3/min) Productivity 2 times! DoForce-Tri's free-cutting inserts reduced vibration at a high speed and doubled the metal removal rate. Tool life (pcs / edge) Tool life 12 times! NMJ, the serrated insert, in optimal grade improves tool life by 6 times. 13

14 MEMO

15 MEMO

16 Tungaloy Corporation (Head office) 11-1 Yoshima-Kogyodanchi Iwaki-city, Fukushima, Japan Phone: Fax: Tungaloy America, Inc N Ventura Drive Arlington Heights,IL 64, U.S.A. Phone: 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 229 Phone: Fax: Tungaloy do Brasil Ltda. Avd. Independencia N4158 Residencial Flora Vinhedo, São Paulo, Brasil Phone: Fax: Tungaloy Germany GmbH An der Alten Ziegelei 1 D-4789 Monheim, Germany Phone: Fax: Tungaloy France S.A.S. ZA Courtaboeuf - Le Rio 1 rue de la Terre de feu F Courtaboeuf Cedex, France Phone: Fax: Tungaloy Italia S.r.I. Via E. Andolfato 1 I-2126 Milano, Italy Phone: Fax: Tungaloy Czech s.r.o. Turanka 115 CZ-627 Brno, Czech Republic Phone: Fax: Tungaloy Ibérica S.L. C/Miquel Servet, 43B, Nau 7 Pol. Ind. Bufalvent ES-8243 Manresa (BCN), Spain Phone: Fax: Tungaloy Scandinavia AB Bultgatan Kungälv, Sweden Phone: Tungaloy Rus, LLC 36-D Harkovsky Lane 389 Belgorod, Russia Phone: Fax: Tungaloy East LLC Stachek str., h.4, office 2, Ekaterinburg, 6217, Russia Phone: Fax: Tungaloy Polska Sp. z o.o. ul. Genewska Warszawa, Poland Phone: Fax: Tungaloy U.K. Ltd The Technology Centre, Wolverhampton Science Park Glaisher Drive, Wolverhampton West Midlands WV1 9RU, UK Phone: Fax: salesinfo@tungaloyuk.co.uk Tungaloy Hungary Kft Erzsébet királyné útja 125 H-1142 Budapest, Hungary Phone: Fax: info@tungaloytools.hu Tungaloy Turkey Dudullu OSB 4. Cad No: Ümraniye Istanbul, TURKEY Phone: Fax: info@tungaloy.com.tr Tungaloy Benelux b.v. Tjalk 7 NL-2411 NZ Bodegraven, Netherlands Phone: Fax: Tungaloy Croatia Josipa Kozarca Bregana, Croatia Phone: Fax: Tungaloy Cutting Tool (Shanghai) Co.,Ltd. Rm No 41 No.88 Zhabei Jiangchang No.3 Rd Shanghai 2436, China Phone: Fax: Tungaloy Cutting Tool (Thailand) Co.,Ltd. Interlink tower 4th Fl. 1858/5-7 Bangna-Trad Road km.5 Bangna, Bangna, Bangkok 126 Thailand Phone: Fax: Tungaloy Singapore (Pte.), Ltd. 62 Ubi Road 1, #6-11 Oxley BizHub 2 Singapore Phone: Fax: Tungaloy Vietnam LE 4-38, Lexington Residence 67 Mai Chi Tho, Dist. 2, Ho Chi Minh City, Vietnam Phone: Fax: Tungaloy India Pvt. Ltd. Indiabulls Finance Centre, Unit # 92-A, 9th Floor, Tower 1, Senapati Bapat Marg, Elphinstone Road (West), Mumbai -413, India Phone: Fax: Tungaloy Korea Co., Ltd #1312, Byucksan Digital Valley 5-cha Beotkkot-ro 244, Geumcheon-gu Seoul, Korea Phone: Fax: Tungaloy Malaysia Sdn Bhd 5 K-2, Kelana Mall, Jalan SS6/14 Kelana Jaya, 4731 Petaling Jaya, Selangor Darul Ehsan Malaysia Phone: Fax: Tungaloy Australia Pty Ltd PO Box 2232, Rowville, Victoria 3178, Australia Phone: Fax: PT. Tungaloy Indonesia Kompleks Grand Wisata Block AA-1 No.3-5 Cibitung Bekasi 1751, Indonesia Phone: Fax: follow us at: facebook.com/tungaloyjapan twitter.com/tungaloyjapan To see this product in action visit: Distributed by: DOWNLOAD Dr. Carbide App AS91 Certifi ed ISO141 Certifi ed EC97J Produced from Recycled paper May. 217 (TJ)

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